591 - Fabrication of Gelatin-Based 3D-Printed Tissue Phantoms for Catheter Device Validation

Purpose: Demonstrate design, fabrication, and characterization of cost-effective, gelatin-based tissue phantoms for interventional radiology device testing, with a case study of catheter anti-dislodgement device testing, emphasizing control of mechanical and ultrasound properties through formulation parameters.

Materials and Methods: Anatomical geometries from the NIH 3D portal were converted to hollow, two-part molds in Fusion 360 and printed in PLA. Type A gelatin (250 Bloom) was bloomed for 120 minutes at 24 °C, then dissolved in 60 °C water at a 1:6 (w/w) ratio. Formulation included 5% (v/v) glycerol to modulate elasticity and 1% (w/v) graphite for ultrasound backscatter. Oil-coated molds were filled, refrigerated for 12 hours, and phantoms stored in saline at 4 °C. A porcine skin layer was adhered with cyanoacrylate and the assembly secured to a wooden base with rope. Characterization comprised unconfined compression testing (Young’s modulus) and B-mode ultrasound to estimate attenuation and visualize organ models. Hands-on time and material costs were recorded.

Results: Phantoms demonstrated soft-tissue-like stiffness (Young’s modulus 22.8 kPa) and acoustic behavior (attenuation ≈0.4 dB/cm/MHz). Ultrasound showed crisp artificial kidney boundaries and reliable needle/catheter tip visualization without obscuring artifacts, enabling guided access and tract creation. Adjusting glycerol and graphite provided predictable tuning of elasticity and backscatter for target property matching. CAD-to-print molds yielded anatomically faithful geometries with smooth internal lumens compatible with standard guidewires and catheters. Assemblies tolerated repeated puncture, dilation, and catheter exchanges within single bench sessions without porcine-skin delamination or gel fracture, and remained hydrated and mechanically stable during testing when stored in saline. Total hands-on fabrication time was ~3 h, and material costs were < $30 per phantom.

Conclusion: A simple CAD-guided casting workflow yields anatomically faithful, tunable, and inexpensive gelatin phantoms that reproduce the tactile resistance and ultrasound appearance of soft tissues. This approach lowers cost barriers and provides scalable support for training, device development, and catheter validation.