Development of a patient-specific chest computed tomography imaging phantom with realistic lung lesions using silicone casting and three-dimensional printing

The validation of the accuracy of the quantification software in computed tomography (CT) images is very challenging. Therefore, we proposed a CT imaging phantom that accurately represents patient-specific anatomical structures and randomly integrates various lesions including disease-like patterns and lesions of various shapes and sizes using silicone casting and three-dimensional (3D) printing. Six nodules of various shapes and sizes were randomly added to the patient’s modeled lungs to evaluate the accuracy of the quantification software. By using silicone materials, CT intensities suitable for the lesions and lung parenchyma were realized, and their Hounsfield unit (HU) values were evaluated on a CT scan of the phantom. As a result, based on the CT scan of the imaging phantom model, the measured HU values for the normal lung parenchyma, each nodule, fibrosis, and emphysematous lesions were within the target value. The measurement error between the stereolithography model and 3D-printing phantoms was 0.2 ± 0.18 mm. In conclusion, the use of 3D printing and silicone casting allowed the application and evaluation of the proposed CT imaging phantom for the validation of the accuracy of the quantification software in CT images, which could be applied to CT-based quantification and development of imaging biomarkers.