PixelPrint: Generating Patient-Specific Phantoms for Spectral CT using Dual Filament 3D Printing

In recent years, the importance of spectral CT scanners in clinical settings has significantly increased, necessitating the development of phantoms with spectral capabilities. This study introduces a dual-filament 3D printing technique for the fabrication of multi-material phantoms suitable for spectral CT, focusing particularly on creating realistic phantoms with orthopedic implants to mimic metal artifacts. Previously, we developed PixelPrint for creating patient-specific lung phantoms that accurately replicate lung properties through precise attenuation profiles and textures. This research extends PixelPrint's utility by incorporating a dual-filament printing approach, which merges materials such as calcium-doped Polylactic Acid (PLA) and metal-doped PLA, to emulate both soft tissue and bone, as well as orthopedic implants. The PixelPrint dual-filament technique utilizes an interleaved approach for material usage, whereby alternating lines of calcium-doped and metal-doped PLA are laid down. The development of specialized filament extruders and deposition mechanisms in this study allows for controlled layering of materials. The effectiveness of this technique was evaluated using various phantom types, including one with a dual filament orthopedic implant and another based on a human knee CT scan with a medical implant. Spectral CT scanner results demonstrated a high degree of similarity between the phantoms and the original patient scans in terms of texture, density, and the creation of realistic metal artifacts. The PixelPrint technology's ability to produce multi-material, lifelike phantoms present new opportunities for evaluating and developing metal artifact reduction (MAR) algorithms and strategies.