Objective: This study aims to investigate the use of 3D printing techniques for the fabrication of physical breast phantoms, suitable for conventional and phase contrast breast imaging. Such phantoms could provide essential information for the design, development and optimization of emerging X-ray imaging modalities. Materials and Methods: Physical phantoms were constructed using two 3D printing techniques: Fused Deposition Modeling and Stereolithography. Eight materials suitable for 3D printing, including thermoplastic filaments and photopolymer resins, were investigated for the optimal representation of breast tissues, based on their attenuation and refractive characteristics. The phantoms consisted of a 3D-printed mold, which was then manually filled with paraffin wax. Additionally, a 3D complex-patterned layer and details representing abnormalities were embedded in different depths. Images of the phantoms were obtained in attenuation and phase contrast mode. Experiments were conducted using an X-ray microfocus tube with Tungsten anode set to 55kVp, combined with a photon-counting detector. The distance between source and detector was 56.5cm. The images were acquired at different object-to-detector distances starting from 5cm up to 40cm in a free space propagation set-up. Results and Conclusion: Results show that among all combinations with paraffin used as an adipose substitute, phantoms created with the Stereolithography technique and resins (especially Flex) as glandular equivalent, were found to be more appropriate for both attenuation and phase contrast imaging. The edge enhancement effect was well observed in the experimental images acquired at 35cm object-to-detector distance, indicating the potential for improved feature visualization using this set-up in phase contrast compared to attenuation mode.
Purpose – The purpose of this paper is to develop a realistic computational model of carbon fibre reinforced polymer (CFRP) structures dedicated for in-silico investigations of the use of X-ray-based imaging techniques as non-destructive testing (NDT) of CFRP parts. Design/methodology/approach – CFRPs contain layers of carbon-fibres bundles within resin. Bundles’ orientation in the different layers is arranged with respect to each other at a well-defined primary direction. In the model, the bundle was simulated as a circular cylinder. The resulted model is a stack of layers of unidirectional bundles having orientation of 0°/90°/45°/−45°. Two CFRP structures were modelled: a flat CFRP part and a real shaped CFRP clip. A porous layer and non-carbon fibres were inserted within each model, respectively. X-ray projection images were generated with a dedicated simulation programme. Three setups were investigated: radiography, tomosynthesis and cone-beam CT (CBCT). Findings – Results showed that porosity and non-carbon fibres were visible with all X-ray-based techniques. Tomosynthesis and CBCT, however, provide higher quality image of defects. Practical implications – The CFRP computational model is a valuable tool in design, testing and optimization phase of X-ray-based imaging techniques for use in NDT of composite materials. Simulated images are generated within a short time; thus results from virtual optimization and testing are obtained very fast and at low cost. Originality/value – An innovative computational model of CFRP structures, dedicated for X-ray imaging simulations, has been developed. The model is characterized by simplicity in its creation and realistic visual appearance of the produced X-ray images.
A methodology for generation of realistic three-dimensional software models of carbon fiber-reinforced polymer (CFRP) structures, dedicated for use in simulation studies of advanced X-ray imaging techniques for non-destructive testing (NDT), has been developed, implemented, and evaluated. Two CFRP models are presented in this paper, one built as a set of stacked layers that contain continuous carbon bundles and a second as a braided textile from woven carbon bundles. The following CFRP defects were modeled: porosity, missing carbon bundles, and non-carbon inclusions. X-ray projection images were generated using an in-house developed X-ray imaging simulator. The obtained preliminary visual and quantitative validation results showed an overall good correlation of characteristics between synthetic and experimental data radiographs and justify the use of this model for research in CFRP X-ray imaging. The application of the CFRP model is demonstrated in a feasibility study that aims to computationally evaluate the appropriateness of two advanced X-ray imaging techniques: cone-beam CT (CBCT) and tomosynthesis (limited arc tomography), as inspection techniques for NDT of CFRP parts. The simulation showed that in all cases the CBCT approach outperformed both conventional radiography and tomosynthesis in terms of defect characterization and visualization.
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