3D-Printed Radiological Phantom Formulation for CT Radiopacity
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Solution Overview
Problem
Current additive manufacturing methods for radiological phantoms lack radiopaque agents, resulting in low radiopacity, limiting their ability to accurately evaluate and calibrate radioimaging devices.
Innovation Solution
Development of novel formulations containing curable materials and radiopaque elements, such as barium sulfate nanoparticles, to achieve enhanced radiopacity in 3D objects, suitable for 3D inkjet printing, with Hounsfield units exceeding 100 HU at 70 kV.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional additive manufacturing materials are used, then the manufacturing process is simple and materials are readily available, but the radiopacity is insufficient for accurate radioimaging device evaluation
Solution Approach 1:
The patent employs composite materials by combining curable resin base materials with radiopaque fillers (barium sulfate, zinc oxide, titanium dioxide) to create a formulation that achieves both high radiopacity (>100 HU) and manufacturability. This composite approach resolves the contradiction by integrating multiple functional components into a single usable material system.
Solution Approach 2:
The patent modifies material parameters by adjusting the concentration and particle size distribution of radiopaque fillers within the formulation. By optimizing these parameters, the formulation achieves enhanced radiopacity while maintaining compatibility with standard additive manufacturing processes, thus improving reliability without excessive complexity.
2Reliability
If radiopaque agents are added to enhance radiopacity, then the radiological evaluation accuracy improves, but the material viscosity and printability may deteriorate
Solution Approach 1:
The patent applies local quality by using a multi-component filler system where different radiopaque materials (barium sulfate, zinc oxide, titanium dioxide) with varying particle sizes and densities are combined. This local optimization of filler properties ensures adequate radiopacity enhancement while maintaining overall material flow and printability characteristics.
Solution Approach 2:
The formulation incorporates porous or hollow radiopaque particles that provide high radiopacity per unit volume while reducing the overall filler loading required. This approach maintains material processability and printability while achieving the necessary radiological properties for accurate evaluation.
3Reliability
If high concentrations of radiopaque fillers are used to maximize radiopacity, then the radiological performance improves, but the curing efficiency and mechanical properties may deteriorate
Solution Approach 1:
The patent uses a balanced composite formulation where radiopaque fillers are combined with reactive diluents and oligomers that serve both as matrix materials and radiopacity contributors. This composite structure distributes stress more effectively and maintains mechanical integrity even at high filler loadings required for maximum radiopacity.
Solution Approach 2:
The formulation includes coupling agents and surface-modified filler particles that act as intermediaries between the radiopaque fillers and the polymer matrix. These intermediaries improve interfacial adhesion and stress transfer, preventing mechanical property deterioration despite high filler concentrations needed for optimal radiopacity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The formulations provide 3D objects with improved radiopacity, enabling more accurate evaluation and calibration of radioimaging devices, surpassing the radiopacity of currently available phantoms.
Implementation Method 1
The formulation comprises: one or more curable materials; and a radiopaque material, the formulation featuring, when hardened, a CT number of at least 100 HU at 70 kV
Implementation Method 2
Such techniques are generally performed by layer by layer deposition and solidification of one or more building materials, typically photopolymerizable (photocurable) materials
Data Source
AI summary
A formulation usable as a modeling material formulation in additive manufacturing of a three-dimensional object and additive manufacturing methods utilizing same are provided. The formulation comprises one or more curable materials; and a radiopaque material, and features, when hardened, a CT number of at least 100 HU at 70 kV. Objects made by the additive manufacturing method utilizing the formulation are usable as radiological phantoms.