Introduction Optical three‐dimensional scanning devices can produce geometrically accurate, high‐resolution models of patients suitable for clinical use. This article describes the use of a metrology‐grade structured light scanner for the design and production of radiotherapy medical devices and synthetic water‐equivalent computer tomography images. Methods Following commissioning of the device by scanning objects of known properties, 173 scans were performed on 26 volunteers, with observations of subjects and operators collected. Results The fit of devices produced using these scans was assessed, and a workflow for the design of complex devices using a treatment planning system was identified. Conclusions Recommendations are provided on the use of the device within a radiation oncology department.

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