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Rapid prototyping fabrication of focused ultrasound transducers

机译：聚焦超声换能器的快速原型制造

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摘要

Rapid prototyping (RP) fabrication techniques are currently widely used in diverse industrial and medical fields, providing substantial advantages in development time and costs in comparison to more traditional manufacturing processes. This paper presents a new method for the fabrication of high-intensity focused ultrasound transducers using RP technology. The construction of a large-aperture hemispherical transducer designed by computer software is described to demonstrate the process. The transducer was conceived as a modular design consisting of 32 individually focused 50.8-mm (2-in) PZT-8 element modules distributed in a 300-mm hemispherical scaffold with a geometric focus of 150 mm. The entire structure of the array, including the module housings and the hemispherical scaffold was fabricated through a stereolithography (SLA) system using a proprietary photopolymer. The PZT elements were bonded to the lenses through a quarter-wave tungsten-epoxy matching layer developed in-house specifically for this purpose. Modules constructed in this manner displayed a high degree of electroacoustic consistency, with an electrical impedance mean and standard deviation of 109 ?? 10.2 :9; for the 32 elements. Time-of-flight measurements for individually pulsed modules mounted on the hemispherical scaffold showed that all pulses arrived at the focus within a 350 ns range, indicating a good degree of element alignment. Pressure profile measurements of the fully assembled transducer also showed close agreement with simulated results. The measured focal beam FWHM dimensions were 1.9 ?? 4.0 mm (1.9 ?? 3.9 mm simulated) in the transversal and axial directions respectively. Total material expenses associated with the construction of the transducer were approximately 5000 USD (as of 2011). The versatility and lower fabrication costs afforded by RP methods may be beneficial in the development of complex transducer geometries suitable for a variety of research and clinical applic- tions.
机译：快速原型（RP）制造技术目前广泛用于各种工业和医学领域，与更传统的制造工艺相比，在开发时间和成本上具有实质优势。本文提出了一种使用RP技术制造高强度聚焦超声换能器的新方法。描述了由计算机软件设计的大口径半球换能器的构造以演示该过程。该换能器被认为是一种模块化设计，由32个单独聚焦的50.8毫米（2英寸）PZT-8元件模块组成，这些模块分布在300毫米半球形支架中，几何焦点为150毫米。阵列的整个结构，包括模块外壳和半球形支架，都是使用专有的光敏聚合物通过立体光刻（SLA）系统制造的。通过内部专门为此目的开发的四分之一波长钨-环氧树脂匹配层将PZT元件粘合到镜片上。以这种方式构造的模块显示出高度的电声一致性，平均电阻抗和标准偏差为109Ω。 10.2：9;对于32个元素。对安装在半球形支架上的单个脉冲模块的飞行时间测量表明，所有脉冲均在350 ns范围内到达焦点，表明元件的对准程度很高。完全组装的换能器的压力曲线测量结果也与模拟结果非常吻合。测得的光束FWHM尺寸为1.9Ω横向和轴向分别为4.0毫米（模拟为1.9毫米至3.9毫米）。与换能器的制造相关的总材料费用约为5000美元（截至2011年）。 RP方法所提供的多功能性和较低的制造成本可能对开发适用于各种研究和临床应用的复杂换能器几何形状有益。

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