SYSTEMS AND METHODS OF THREE-DIMENSIONAL PRINTING OF COLLIMATORS USING ADDITIVE APPROACHES
20220236716 · 2022-07-28
Inventors
Cpc classification
G05B19/4099
PHYSICS
B33Y10/00
PERFORMING OPERATIONS; TRANSPORTING
B33Y80/00
PERFORMING OPERATIONS; TRANSPORTING
G05B2219/49023
PHYSICS
B33Y50/02
PERFORMING OPERATIONS; TRANSPORTING
B29L2011/00
PERFORMING OPERATIONS; TRANSPORTING
B29C64/393
PERFORMING OPERATIONS; TRANSPORTING
International classification
G05B19/4099
PHYSICS
B29C64/393
PERFORMING OPERATIONS; TRANSPORTING
B33Y50/02
PERFORMING OPERATIONS; TRANSPORTING
B33Y80/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Systems and methods to manufacture a collimator include deposition of a first layer of material in a first pattern, the first pattern comprising a first plurality of substantially parallel lines oriented in a first direction, and deposition of a second layer of material in a second pattern directly upon the first layer of material, the second pattern comprising a second plurality of substantially parallel lines oriented in a second direction different from the first direction. An area bounded by a first pair of the first plurality of substantially parallel lines and a second pair of the second plurality of substantially parallel lines intersecting the first pair defines a septum of the collimator.
Claims
1. A method of manufacturing a collimator using a three-dimensional printer, the method comprising: operating the three-dimensional printer to deposit a first layer of material of the collimator in a first pattern, the first pattern comprising a first plurality of substantially parallel lines oriented in a first direction; and operating the three-dimensional printer to deposit a second layer of material of the collimator in a second pattern, the second pattern comprising a second plurality of substantially parallel lines oriented in a second direction different from the first direction, wherein an area bounded by a first pair of the first plurality of substantially parallel lines and a second pair of the second plurality of substantially parallel lines intersecting the first pair defines a septum of the collimator.
2. The method of claim 1, wherein the first pattern comprises a first plurality of turns and the second pattern comprises a second plurality of turns, and wherein the first plurality of turns and the second plurality of turns are outside of a field-of-view of the collimator.
3. The method of claim 1, further comprising: operating the three-dimensional printer to deposit a third layer of material of the collimator in a third pattern, the third pattern comprising a third plurality of substantially parallel lines oriented in a third direction different from the first direction and the second direction, wherein the area is bounded by the first pair of the first plurality of substantially parallel lines, the second pair of the second plurality of substantially parallel lines, and a third pair of the third plurality of substantially parallel lines intersecting the first pair and the second pair.
4. The method of claim 3, wherein the first pattern comprises a first plurality of turns, the second pattern comprises a second plurality of turns, and the third pattern comprises a third plurality of turns, wherein the first plurality of turns, the second plurality of turns and the third plurality of turns are outside of a field-of-view of the collimator.
5. The method of claim 4, wherein the first pattern, the second pattern, and the third pattern are different from each other, and wherein the second direction is rotated sixty degrees clockwise from the first direction and the third direction is rotated sixty degrees counterclockwise from the first direction.
6. The method of claim 3, wherein the first pattern, the second pattern, and the third pattern are different from each other.
7. The method of claim 3, wherein the second direction is rotated sixty degrees clockwise from the first direction and the third direction is rotated sixty degrees counterclockwise from the first direction.
8. A non-transitory computer-readable medium having stored thereon instructions which when executed by a processor cause the processor to perform a method of manufacturing a collimator, the method comprising: depositing a first layer of material in a first pattern, the first pattern comprising a first plurality of substantially parallel lines oriented in a first direction; and depositing a second layer of material in a second pattern directly upon the first layer of material, the second pattern comprising a second plurality of substantially parallel lines oriented in a second direction different from the first direction, wherein an area bounded by a first pair of the first plurality of substantially parallel lines and a second pair of the second plurality of substantially parallel lines intersecting the first pair defines a septum of the collimator.
9. The medium of claim 8, wherein the first pattern comprises a first plurality of turns and the second pattern comprises a second plurality of turns, and wherein the first plurality of turns and the second plurality of turns are outside of a field-of-view of the collimator.
10. The medium of claim 8, the method further comprising: depositing a third layer of material in a third pattern directly upon the second layer of material, the third pattern comprising a third plurality of substantially parallel lines oriented in a third direction different from the first direction and the second direction, wherein the area is bounded by the first pair of the first plurality of substantially parallel lines, the second pair of the second plurality of substantially parallel lines, and a third pair of the third plurality of substantially parallel lines intersecting the first pair and the second pair.
11. The medium of claim 10, wherein the first pattern comprises a first plurality of turns, the second pattern comprises a second plurality of turns, and the third pattern comprises a third plurality of turns, wherein the first plurality of turns, the second plurality of turns and the third plurality of turns are outside of a field-of-view of the collimator.
12. The medium of claim 11, wherein the first pattern, the second pattern, and the third pattern are different from each other, and wherein the second direction is rotated sixty degrees clockwise from the first direction and the third direction is rotated sixty degrees counterclockwise from the first direction.
13. The medium of claim 10, wherein the first pattern, the second pattern, and the third pattern are different from each other.
14. The medium of claim 10, wherein the second direction is rotated sixty degrees clockwise from the first direction and the third direction is rotated sixty degrees counterclockwise from the first direction.
15. A system comprising: a memory storing processor-executable instructions; and a processor to execute the instructions to: generate a three-dimensional print file of a collimator comprising: a first pattern, the first pattern comprising a first plurality of substantially parallel lines oriented in a first direction; and a second pattern, the second pattern different from the first pattern and comprising a second plurality of substantially parallel lines oriented in a second direction different from the first direction, wherein an area bounded by a first pair of the first plurality of substantially parallel lines and a second pair of the second plurality of substantially parallel lines intersecting the first pair defines a septum of the collimator; and transmit the three-dimensional print file to a three-dimensional printer.
16. The system of claim 15, wherein the first pattern comprises a first plurality of turns and the second pattern comprises a second plurality of turns, and wherein the first plurality of turns and the second plurality of turns are outside of a field-of-view of the collimator.
17. The system of claim 15, wherein the three-dimensional print file comprises: a third pattern, the third pattern comprising a third plurality of substantially parallel lines oriented in a third direction different from the first direction and the second direction, wherein the area is bounded by the first pair of the first plurality of substantially parallel lines, the second pair of the second plurality of substantially parallel lines, and a third pair of the third plurality of substantially parallel lines intersecting the first pair and the second pair.
18. The system of claim 17, wherein the first pattern comprises a first plurality of turns, the second pattern comprises a second plurality of turns, and the third pattern comprises a third plurality of turns, wherein the first plurality of turns, the second plurality of turns and the third plurality of turns are outside of a field-of-view of the collimator.
19. The system of claim 18, wherein the first pattern, the second pattern, and the third pattern are different from each other, and wherein the second direction is rotated sixty degrees clockwise from the first direction and the third direction is rotated sixty degrees counterclockwise from the first direction.
20. The system of claim 17, wherein the second direction is rotated sixty degrees clockwise from the first direction and the third direction is rotated sixty degrees counterclockwise from the first direction.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
DETAILED DESCRIPTION
[0018] Embodying systems and methods implement one or more layered-permutation sequence algorithms that specify the content of a stereolithography (“STL”) file used to instruct a 3D printer to produce a collimator using an additive, layered process. The printed collimator is extruded layer by layer using 3D printer filament, to form a collimator of suitable thickness for its intended medical modality. Systems and methods specify each layer representation within the STL file in a predetermined order to achieve a collimator capable of operating within required performance specifications.
[0019] A collimator manufactured by these techniques can be applicable for various medical modalities (e.g., SPECT, CT, and others). For purposes of this disclosure, a SPECT system collimator will be discussed. However, the invention is not so limited, it should be readily understood that other medical-modality collimators are within the scope of this disclosure.
[0020] In accordance with embodiments, a 3D printed collimator with required tolerances and overall quality, and having a large field-of-view can be produced using off-the-shelf components from an STL file created by embodying algorithms. Embodying system and methods can have direct applications in fast-prototyping operable collimators for test/prove-out of new designs. Embodying approaches distinguish over conventional techniques by being able to quickly print and test new collimator designs (for performance compatibility/impact with improved image reconstruction algorithms).
[0021] This distinction over the prior art can be of great value to improving current and future SPECT systems and applications. Embodying systems and methods make possible the manufacture of medium-energy SPECT collimators using commercially available 3D printing off-the-shelf components.
[0022]
[0023]
[0024] As illustrated by the examples of
[0025] Drawbacks in the conventional approaches result from, for example, the 3D printhead is required to re-trace itself along the same path during the additive process detailed in the conventional STL file; and/or maneuvering through sharp turns (e.g., about 60° or greater) during its trajectory. These features are not properly achieved when created by a 3D printer extruding conventional materials per information provided by a conventional STL file.
[0026]
[0027] Layer 310 depicts a printhead path with two connected sets of about parallel lines, where one set of lines is orthogonal to the other. The printhead moves along the trajectory path. Layer 320 depicts a printhead path with one set of lines rotated clockwise diagonally (about 60°) from its position in layer 310. Similarly, layer 320 depicts a printhead path with the same set of lines rotated counterclockwise diagonally (about −60°) from its position in layer 310.
[0028] The triangular-hole predicted cumulative deposit 340 is formed by stacking successive groupings of these three different layers 310, 320, 330 one grouping after the other grouping. These layers are positioned relative to each other with respect to the horizontal plane of deposit so that the overlapping portions of the 3D-printed layers intercept at about their center. In accordance with embodiments, the groupings can follow a non-repeating permutation sequence; or a random sequence.
[0029] The trajectory path for each of the multiple layers is determined by an embodying algorithm (described below). The algorithm receives design specification parameters for a medical-modality collimator. The design specifications can be in the form of a CAD file describing the design of the collimator to be printed on the 3D printer. In other implementations, the design specifications can be stored as one or more database records (e.g., objects, tabular data, etc.), or other formats.
[0030]
[0031] The conventional, synthesized cumulative result illustrated in
[0032] In accordance with embodiments, a physical collimator represented by synthesized cumulative result 390 can be produced by stacking groupings of printer path layer 310, printer path layer 320, and printer path layer 330 to create triangular patterns. The deposition of the extruded material within the collimator's field-of-view is along straight lines, with all turns made outside the field-of-view. Multiple renditions of the stacked grouped layers are deposited to build the septa walls to the desired height. In accordance with implementations, collimators with hexagonal, square, triangular, or other perimeter channels can be produced.
[0033] In accordance with embodiments, the ordering of the multiple paths within each stacked grouping can be varied between groups. In some implementations, the ordering within a stack grouping can be sequential (e.g., ABC, ABC, ABC, . . . ), stepped (e.g., ABC, BCA, CAB, . . . ), random (ABC, BAC, CBA, . . . ), or a non-repeating permutation—where “A”, “B” and “C” represent different types of 3D printhead trajectory path patterns (e.g., layers 310, 320, 330). The variation in stack grouping can reduce manufacturing imaging artifacts in the 3D printed collimator, thus improving its overall performance. The thickness of layers, and/or successive layers can also reduce manufacturing imaging artifacts and, thus, improve the collimator performance.
[0034] For a given design specification of a medical-modality collimator, the following parameters can be determined: [0035] p!: the number of permutations of p types of layers without repetition; [0036] n: the number of 3D printed layers; [0037] p: the number of types of layers; [0038] d: the thickness of a 3D-printed layer; and [0039] t: the overall collimator thickness.
[0040] For example, for a triangular-hole collimator, p=3 (layers) and p!=6 (quantity of layer permutation types). In accordance with one implementation, the sequence of permutations can be: [0041] Layer grouping permutation #1: [A,B,C]; [0042] Layer grouping permutation #2: [B,A,C]; [0043] Layer grouping permutation #3: [C,A,B]; [0044] Layer grouping permutation #4: [A,C,B]; [0045] Layer grouping permutation #5: [B,C,A]; [0046] Layer grouping permutation #6: [C,A,B].
[0047] Based on the collimator design specifications, embodying systems and methods can determine the number of layer permutations, and the grouping pattern for within each layer. For example, a non-repeating permutation sequence can be determined as follows:
[0048] The quantity of non-repeating permutation sequences (l) can be pre-generated for storage in memory:
[0049] Where k.sub.l represents the quantity of elements of the l.sup.th permutation sequence. For instance, for p=3,
[0050] k.sub.0=18: [0051] [A,B,C,B,A,C,C,A,B,A,C,B,B,C,A,C,A,B]
[0052] k.sub.1=108: [0053] [A,B,C,B,A,C,C,A,B,A,C,B,B,C,A,C,A,B,C,A,B,A,C,B,A,B,C,B,A,C,B, C,A,C,A,B,B,C,A,C,A,B,A,B,C,B,A,C,C,A,B,A,C,B,A,B,C,B,A,C,B,C, A,C,A,B,C,A,B,A,C,B,C,A,B,A,C,B,B,C,A,C,A,B,A,B,C,B,A,C,B,C,A, C,A,B,A,B,C,B,A,C,C,A,B,A,C,B]
[0054] and, k.sub.2=648: [0055] [A,B,C,B,A,C,C,A,B,A,C,B,B,C,A,C,A,B,C,A,B,A,C,B,A,B,C,B,A,C,B, C,A,C,A,B,B,C,A,C,A,B,A,B,C,B,A,C,C,A,B,A,C,B,A,B,C,B,A,C,B,C, A,C,A,B,C,A,B,A,C,B,C,A,B,A,C,B,B,C,A,C,A,B,A,B,C,B,A,C,B,C,A, C,A,B,A,B,C,B,A,C,C,A,B,A,C,B,B,C,A,C,A,B,A,B,C,B,A,C,C,A,B,A, C,B,A,B,C,B,A,C,B,C,A,C,A,B,C,A,B,A,C,B,A,B,C,B,A,C,C,A,B,A,C, B,B,C,A,C,A,B,C,A,B,A,C,B,A,B,C,B,A,C,B,C,A,C,A,B,C,A,B,A,C,B, B,C,A,C,A,B,A,B,C,B,A,C,B,C,A,C,A,B,A,B,C,B,A,C,C,A,B A,C,B,C, A,B,A,C,B,B,C,A,C,A,B,A,B,C,B,A,C,B,C,A,C,A,B,A,B,C,B,A,C,C,A, B,A,C,B,A,B,C,B,A,C,C,A,B,A,C,B,B,C,A,C,A,B,C,A,B,A,C,B,A,B,C, B,A,C,B,C,A,C,A,B,B,C,A,C,A,B,A,B,C,B,A,C,C,A,B,A,C,B,A,B,C,B, A,C,B,C,A,C,A,B,C,A,B,A,C,B,A,B,C,B,A,C,C,A,B,A,C,B,B,C,A,C,A, B,C,A,B,A,C,B,A,B,C,B,A,C,B,C,A,C,A,B,C,A,B,A,C,B,B,C,A,C,A,B, A,B,C,B,A,C,B,C,A,C,A,B,A,B,C,B,A,C,C,A,B,A,C,B,B,C,A,C,A,B,A, B,C,B,A,C,C,A,B,A,C,B,A,B,C,B,A,C,B,C,A,C,A,B,C,A,B,A,C,B,B,C, A,C,A,B,A,B,C,B,A,C,C,A,B,A,C,B,A,B,C,B,A,C,B,C,A,C,A,B,C,A,B, A,C,B,C,A,B,A,C,B,B,C,A,C,A,B,A,B,C,B,A,C,B,C,A,C,A,B,A,B,C,B, A,C,C,A,B,A,C,B,A,B,C,B,A,C,C,A,B,A,C,B,B,C,A,C,A,B,C,A,B,A,C, B,A,B,C,B,A,C,B,C,A,C,A,B,C,A,B,A,C,B,B,C,A,C,A,B,A,B,C,B,A,C, B,C,A,C,A,B,A,B,C,B,A,C,C,A,B,A,C,B,A,B,C,B,A,C,C,A,B,A,C,B,B, C,A,C,A,B,C,A,B,A,C,B,A,B,C,B,A,C,B,C,A,C,A,B,B,C,A,C,A,B,A,B, C,B,A,C,C,A,B,A,C,B,A,B,C,B,A,C,B,C,A,C,A,B,C,A,B,A,C,B]
[0056] These sequences are generated using permutations of previously permutated sequences. The following is an embodying step-by-step description:
[0057] 1) Beginning with different types of layers A, B, C (e.g., layer 310, layer 320, layer 330), define an initial set of sequences A′, B′ and C′ (e.g., A′=A, B′=B, and C′=C): A′=[A], B′=[B], C′=[C];
[0058] 2) Generate a non-repeating sequence of “ABC's” based on previous values of “A′B′C′s”, obtained from Step 1, where the base permutation sequence (A′B′C′) does not change: [A′,B′,C′]; [B′,A′,C′]; [C′,A′,B′]; [A′,C′,B′]; [B′,C′,A′]; [C′,A′,B′];
[0059] 3) Define new values for A′, B′ and C′, based on the previous step, by subdividing the previous sequence into three consecutive regions: A′=[A,B,C,B,A,C], B′=[C,A,B,A,C,B], C′=[B,C,A,C,A,B] (see k=18 above);
[0060] 4) Generate a non-repeating sequence of “ABC's” based on values of “A′B′C′s” obtained from previous step, where the base permutation sequence “A′B′C′s” does not change: [A′,B′,C′]; [B′,A′,C′]; [C′,A′,B′]; [A′,C′,B′]; [B′,C′,A′]; [C′,A′,B′] (see k.sub.1=108 above);
[0061] 5) Define A′, B′ and C′ with new values, based on previous step, by subdividing the previous sequence in three consecutive regions:
[0062] 6) Generate a non-repeating sequence of ABC based on values of A′B′C′ obtained from the previous step, where the base permutation sequence A′B′C′ does not change: [A′,B′,C′]; [B′,A′,C′]; [C′,A′,B′]; [A′,C′,B′]; [B′,C′,A′]; [C′,A′,B′] (see k.sub.2=648 above)
[0063] 7) Repeat above steps until a sequence is generated to satisfy the design specifications for the collimator based on layer thickness d, and the overall collimator thickness t, (i.e., k>t/d).
[0064] Knowing the pre-generated permutation sequences (steps 1-7), a 3D print sequence for the STL file can be assembled based on a ratio of the overall collimator thickness to the layer thickness (t/d), and the number of members of each permutation (k.sub.i): [0065] If m=(t/d)≤k.sub.0, grab a quantity of m sequence elements from k.sub.0. For instance, if m=12, the sequence of layers can be the first twelve elements of sequence k.sub.0—[A,B,C,B,A,C,C,A,B,A,C,B].
[0066] If k.sub.1≥m=(t/d)>k.sub.0, grab a quantity of m sequence elements from k.sub.1. For instance, if m=30, the sequence of layers consists of the first 30 elements of sequence k.sub.1—[A,B,C,B,A,C,C,A,B,A,C,B,B,C,A,C,A,B,C,A,B,A,C,B,A,B,C,B,A,C].
[0067] If k.sub.2≥m=(t/d)>k.sub.1, grab a quantity of m sequence elements from k.sub.2. For instance, if m=640, the sequence of layers consists of the first 640 elements of sequence k.sub.2.
[0068]
[0069] The design specification parameters for a medical-modality collimator are received, step 410. The parameters can be obtained from a CAD file, database record(s), or other memory and/or file. Parameters can include the collimator channel pattern (e.g., square, triangular, hexagonal, etc.), the septum wall width, overall collimator thickness.
[0070] Determine the number of deposit layer permutation sequence, step 420. The number of layers is related to the number of walls to form the channel (e.g., triangular channel has 3 permutation sequences. Calculate the number of permutation layer elements (1Q) to be deposited for each layer, step 430. The number of permutation layers is related to the deposit layer thickness and the overall collimator design specification thickness. For each permutation layer, step 440, generate a quantity of sequences formed from a base permutation sequence. The quantity of sequences is dependent on the layer thickness.
[0071] Once the sequences for each permutation layer is generated, these permutation layers can be assembled, step 450, to form a 3D printer file, e.g., a STL format file and/or object. The assembled 3D print file can be provided, step 460, to a 3D printer. By following the permutation sequences and layers specified in the 3D print file, a 3D printer can manufacture, step 470, a medical collimator based on the assembled sets of permutation layers.
[0072]
[0073] Layered-sequence algorithm 534 can be executed by the control processor to perform the steps outlined above to create 3D print file 538, which specifies to 3D printer 510 a sequencing of additive layers having permutations within each layer to create the medical modality collimator. The specifications for the medical-modality collimator can be stored in collimator design specification 536, or provide to the control processor across the electronic communication network. Pre-generated permutation sequences 539 may also be stored and accessed by the processor for generating sets of sequences.
[0074] In accordance with some embodiments, a computer program application stored in non-volatile memory or computer-readable medium (e.g., register memory, processor cache, RAM, ROM, hard drive, flash memory, CD ROM, magnetic media, etc.) may include code or executable instructions that when executed may instruct and/or cause a controller or processor to perform methods disclosed herein, such as a method to produce a stereolithography file to instruct a 3D printer to manufacture a 3D printed collimator, as described above.
[0075] The computer-readable medium may be a non-transitory computer-readable media including all forms and types of memory and all computer-readable media except for a transitory, propagating signal. In one implementation, the non-volatile memory or computer-readable medium may be external memory.
[0076] Although specific hardware and methods have been described herein, note that any number of other configurations may be provided in accordance with embodiments of the invention. Thus, while there have been shown, described, and pointed out fundamental novel features of the invention, it will be understood that various omissions, substitutions, and changes in the form and details of the illustrated embodiments, and in their operation, may be made by those skilled in the art without departing from the spirit and scope of the invention. Substitutions of elements from one embodiment to another are also fully intended and contemplated. The invention is defined solely with regard to the claims appended hereto, and equivalents of the recitations therein.