Imaging Properties of Additive Manufactured (3D Printed) Materials for Potential Use for Phantom Models

Tailoring the Mass Density of 3D Printing Materials for Accurate X-ray Imaging Simulation by Controlled Underfilling for Radiographic Phantoms

Additive manufacturing and 3D printing allow for the design and rapid production of radiographic phantoms for X-ray imaging, including CT. These are used for numerous purposes, such as patient simulation, optimization of imaging procedures and dose levels, system evaluation and quality assurance. However, standard 3D printing polymers do not mimic X-ray attenuation properties of tissues like soft, adipose, lung or bone tissue, and standard materials like liquid water. The mass density of printing polymers-especially important in CT-is often inappropriate, i.e., mostly too high. Different methods can be applied to reduce mass density. This work examines reducing density by controlled underfilling either realized by using 3D printing materials expanded through foaming during heating in the printing process, or reducing polymer flow to introduce microscopic air-filled voids. The achievable density reduction depends on the base polymer used. When using foaming materials, density is controlled by the extrusion temperature, and ranges from 33 to 47% of the base polymer used, corresponding to a range of -650 to -394 HU in CT with 120 kV. Standard filaments (Nylon, modified PLA and modified ABS) allowed density reductions by 20 to 25%, covering HU values in CT from -260 to 77 (Nylon), -230 to -20 (ABS) and -81 to 143 (PLA). A standard chalk-filled PLA filament allowed reproduction of bone tissue in a wide range of bone mineral content resulting in CT numbers from 57 to 460 HU. Controlled underfilling allowed the production of radiographic phantom materials with continuously adjustable attenuation in a limited but appropriate range, allowing for the reproduction of X-ray attenuation properties of water, adipose, soft, lung, and bone tissue in an accurate, predictable and reproducible manner.

Computed Tomography Attenuation of Three-Dimensional (3D) Printing Materials-Depository to Aid in Constructing 3D-Printed Phantoms

Three-dimensionally printed phantoms are increasingly used in medical imaging and research due to their cost-effectiveness and customizability, offering valuable alternatives to commercial phantoms. The purpose of this study was to assess the computed tomography (CT) attenuation characteristics of 27 resin materials from Formlabs, a 3D printing equipment and materials manufacturer. Cube phantoms (both solid and hollow constructions) produced with each resin were subjected to CT scanning under varying tube current-time products with attenuation measurements recorded in Hounsfield units (HU). The resins exhibited a wide range of attenuation values (-3.33 to 2666.27 HU), closely mimicking a range of human tissues, from fluids to dense bone structures. The resins also demonstrated consistent attenuation regardless of changes in the tube current. The CT attenuation analysis of FormLabs resins produced an archive of radiological imaging characteristics of photopolymers that can be utilized to construct more accurate tissue mimicking medical phantoms and improve the evaluation of imaging device performance.

Application of MRI and CT Images in Surgical Treatment of Early Cervical Cancer

In order to understand the problems of the application of MRI and CT images in the early cervical cancer surgery, a method that the application of MRI imaging and CT images in early cervical cancer surgery was proposed. For the cervical cancer in clinical practice, the applications of the modern imaging examination and the clinical staging classification were investigated and analyzed. Compared with the surgical pathology results, the application value of common modern imaging in clinical staging of cervical cancer was evaluated. It was found that the sensitivity of MRI and CT in diagnosing lymph node metastasis was 56% and 58%, and the specificity was 93% and 92%, respectively. The experiment proved the application value of MRI and CT in clinical staging of cervical cancer.

Additively manufactured test phantoms for mimicking soft tissue radiation attenuation in CBCT using Polyjet technology

OBJECTIVES

To develop and validate a simple approach for building cost-effective imaging phantoms for Cone Beam Computed Tomography (CBCT) using a modified Polyjet additive manufacturing technology where a single material can mimic a range of human soft-tissue radiation attenuation.

MATERIALS AND METHODS

Single material test phantoms using a cubic lattice were designed in 3-Matic 15.0 software . Keeping the individual cubic lattice volume constant, eight different percentage ratio (R) of air: material from 0% to 70% with a 10% increment were assigned to each sample. The phantoms were printed in three materials, namely Vero PureWhite, VeroClear and TangoPlus using Polyjet technology. The CT value analysis, non-contact profile measurement and microCT-based volumetric analysis was performed for all the samples.

RESULTS

The printed test phantoms produced a grey value spectrum equivalent to the radiation attenuation of human soft tissues in the range of -757 to +286 HU on CT. The results from dimensional comparison analysis of the printed phantoms with the digital test phantoms using non-contact profile measurement showed a mean accuracy of 99.07 % and that of micro-CT volumetric analysis showed mean volumetric accuracy of 84.80-94.91%. The material and printing costs of developing 24 test phantoms was 83.00 Euro.

CONCLUSIONS

The study shows that additive manufacturing-guided macrostructure manipulation modifies successfully the radiographic visibility of a material in CBCT imaging with 1 mm³ resolution, helping customization of imaging phantoms.

Classification of X-Ray Attenuation Properties of Additive Manufacturing and 3D Printing Materials Using Computed Tomography From 70 to 140 kVp

Additive manufacturing and 3D printing is particularly useful in the production of phantoms for medical imaging applications including determination and optimization of (diagnostic) image quality and dosimetry. Additive manufacturing allows the leap from simple slab and stylized to (pseudo)-anthropomorphic phantoms. This necessitates the use of materials with x-ray attenuation as close as possible to that of the tissues or organs mimicked. X-ray attenuation properties including their energy dependence were determined for 35 printing materials comprising photocured resins and thermoplastic polymers. Prior to measuring x-ray attenuation in CT from 70 to 140 kVp, printing parameters were thoroughly optimized to ensure maximum density avoiding too low attenuation due to microscopic or macroscopic voids. These optimized parameters are made available. CT scanning was performed in a water filled phantom to guarantee defined scan conditions and accurate HU value determination. The spectrum of HU values covered by polymers printed using fused deposition modeling reached from −258 to +1,063 at 120 kVp (−197 to +1,804 at 70 kVp, to −266 to +985 at 140 kVp, respectively). Photocured resins covered 43 to 175 HU at 120 kVp (16–156 at 70, and 57–178 at 140 kVp). At 120 kVp, ASA mimics water almost perfectly (+2 HU). HIPS (−40 HU) is found close to adipose tissue. In all photocurable resins, and 17 printing filaments HU values decreased with increasing beam hardness contrary to soft tissues except adipose tissue making it difficult to mimic water or average soft tissue in phantoms correctly over a range of energies with one single printing material. Filled filaments provided both, the HU range, and an appropriate energy dependence mimicking bone tissues. A filled material with almost constant HU values was identified potentially allowing mimicking soft tissues by reducing density using controlled under-filling. The measurements performed in this study can be used to design phantoms with a wide range of x-ray contrasts, and energy dependence of these contrasts by combining appropriate materials. Data provided on the energy dependence can also be used to correct contrast or contrast to noise ratios from phantom measurements to real tissue contrasts or CNRs.

Customized Low-Cost Model for Hands-on Training in Intraoperative Ultrasound for Neurosurgeons: Our Experience and Review of Literature

BACKGROUND

Practical ultrasound (US) training is essential to overcome operator dependence and optimize image acquisition. For intraoperative neurosurgical application, in addition to hand-eye coordination, ultrasound training should incorporate training for visuomotor and visuospatial skills, as well as 3-dimensional depth orientation. Our agar-based, low-cost model has been developed keeping these skill sets in mind.

MATERIALS AND METHODS

We have described preparation of an agar-based, low-cost customizable model using commonly available echogenic objects as targets, which allows the clinician to perform various training tasks like depth insonation, target localization, and biopsy and resection cavity insonation. This low-cost model was implemented for internal training and validated at an international training course.

RESULTS

The cost of the model was 4 USD, and its preparation time was <1 hour. It can be used for performing multiple US training tasks and provides realistic images and good tactile feedback. However, the model is perishable and artifacts are occasionally visible. Feedback survey results showed that >80% of participants felt the model was useful for US training.

CONCLUSIONS

Our customizable low-cost US training model is an effective and efficient tool for US training with high acceptance by neurosurgeons. It faithfully mimics various intraoperative tasks and helps clinicians gain confidence to use intraoperative ultrasound as an adjunct during the procedures. This model can be used by individual surgeons/departments for ongoing training, as well as for larger training courses and workshops.

Simulating Tissues with 3D-Printed and Castable Materials

Manufacturing technologies continue to be developed and utilized in medical prototyping, simulations, and imaging phantom production. For radiologic image-guided simulation and instruction, models should ideally have similar imaging characteristics and physical properties to the tissues they replicate. Due to the proliferation of different printing technologies and materials, there is a diverse and broad range of approaches and materials to consider before embarking on a project. Although many printed materials' biomechanical parameters have been reported, no manufacturer includes medical imaging properties that are essential for realistic phantom production. We hypothesize that there are now ample materials available to create high-fidelity imaging anthropomorphic phantoms using 3D printing and casting of common commercially available materials. A material database of radiological, physical, manufacturing, and economic properties for 29 castable and 68 printable materials was generated from samples fabricated by the authors or obtained from the manufacturer and scanned with CT at multiple tube voltages. This is the largest study assessing multiple different parameters associated with 3D printing to date. These data are being made freely available on GitHub, thus affording medical simulation experts access to a database of relevant imaging characteristics of common printable and castable materials. Full data available at: https://github.com/nmcross/Material-Imaging-Characteristics .