An Enhanced Voxel-by-Voxel Filament Extrusion-Based Method for Realistic Radiological Phantoms: A Breast Phantom Case

This study introduces a novel enhanced voxel-by-voxel fused filament fabrication approach utilizing a custom 3D printer. The key innovation is the simultaneous, real-time manipulation of both filament flow and printing speed per voxel. By adjusting the printing speed proportionally to the extrusion rate, the method ensures sufficient time for precise material deposition, effectively countering under-extrusion effects and significantly improving the process’s responsiveness and accuracy. The method was validated through a calibration process and in the fabrication of a breast phantom derived from a patient’s MRI data. Calibration demonstrated a strong linear correlation between HUs, extrusion rate, and speed, with a coefficient of R = 0.99. CT scans of the phantom confirmed consistent replication of the expected HU distribution and anatomical features, visually demonstrating high correlation with the original patient images. The dual-parameter control strategy successfully enhances the fidelity of soft tissue phantoms fabrication. Future work will focus on adapting the method for high-speed printing and multi-material applications.