Use of light-weight foaming polylactic acid as a lung-equivalent material in 3D printed phantoms

The 3D printing of lung-equivalent phantoms using conventional polylactic acid (PLA) filaments requires the use of low in-fill printing densities, which can produce substantial density heterogeneities from the air gaps within the resulting prints. Light-weight foaming PLA filaments produce microscopic air bubbles when heated to 3D printing temperatures. In this study, the expansion of foaming PLA filament was characterised for two 3D printers with different nozzle diameters, in order to optimise the printing flow rates required to achieve a low density print when printed at 100% in-fill printing density, without noticeable internal air gaps. Effective densities as low as 0.28 g cm − 3 were shown to be achievable with only microscopic air gaps. Light-weight foaming PLA filaments are a cost-effective method for achieving homogeneous lung-equivalency in 3D printed phantoms for use in radiotherapy imaging and dosimetry, featuring smaller air gaps than required to achieve low densities with conventional PLA filaments.