Single-Fiber Transducer Arrays for 3-D Ultrasound Computed Tomography: From Requirements to Results

A potential method for future breast cancer screening is 3-D ultrasound computed tomography (USCT). The utilized image reconstruction algorithms require transducer characteristics fundamentally different from conventional transducer arrays, leading to the necessity of a custom design. This design has to provide random transducer positioning, isotropic sound emission as well as a large bandwidth and wide opening angle. In this article, we present a new transducer array design to be utilized in a third generation 3-D USCT system. Each system requires 128 cylindrical arrays, mounted into the shell of a hemispherical measurement vessel. Each new array contains a 0.6 mm thick disk with 18 single PZT fibers (0.46 mm diameter) embedded in a polymer matrix. Randomized positioning of the fibers is achieved with an arrange-and-fill process. The single-fiber disks are connected on both ends with a matching and backing disk using simple stacking and adhesives. This enables fast and scalable production. We characterized the acoustic field of 54 transducers with a hydrophone. Measurements in 2-D showed isotropic acoustic fields. The mean bandwidth and opening angle are 131% and 42°, respectively (both -10 dB). The large bandwidth arises from two resonances within the utilized frequency range. Parameter studies using different models showed that the realized design is already close to the achievable optimum for the transducer technology used. Two 3-D USCT systems were equipped with the new arrays. First images show promising results, with an increase in image contrast and a significant reduction of artifacts.