Characterization of Commercial and Custom-Made Printing Filament Materials for Computed Tomography Imaging of Radiological Phantoms

In recent years, material extrusion-based additive manufacturing, particularly fused filament fabrication (FFF), has gained significant attention due to its versatility and cost-effectiveness in producing complex geometries. This paper presents the characterization of seven novel materials for FFF and twenty-two commercially available filaments in terms of X-ray computed tomography (CT) numbers, as tissue mimicking materials for the realization of 3D printed radiological phantoms. Two technical approaches, by 3D printing of cube samples and by producing cylinders of melted materials, are used for achieving this goal. Results showed that the CT numbers, given in Hounsfield unit (HU), of all the samples depended on the beam kilovoltage (kV). The CT numbers ranged from +411 HU to +3071 HU (at 80 kV), from −422 HU to +3071 HU (at 100 kV), and from −442 HU to +3070 HU (at 120 kV). Several commercial and custom-made filaments demonstrated suitability for substituting soft and hard human tissues, for realization of 3D printed phantoms with FFF in CT imaging. For breast imaging, an anthropomorphic phantom with two filaments could be fabricated using ABS-C (conductive acrylonitrile butadiene styrene) as a substitute for breast adipose tissue, and ASA-A (acrylic styrene acrylonitrile) for glandular breast tissue.