3D Printed Medical Phantoms: Institute for Multiscale Simulation Case Study

This case study covers the FDM failure, the SLS switch, and what the project means for Australian universities today.

How the lab uses 3D printed medical phantoms for SPECT imaging research

The Institute for Multiscale Simulation, known as MSS, was established in 2009 inside the Department of Chemical and Biological Engineering at Friedrich-Alexander-Universität in Germany. Around 100 students cycle through Dr. Patric Müller's 3D printing courses each year. Research collaborations cover granulate dynamics, multiscale numerical simulation, and medical imaging.

A medical phantom is a physical model built to mimic the radiological properties of human tissue. Research teams use phantoms to calibrate scanners and validate imaging protocols. For MSS, the target was a brain phantom precise enough to test single-photon emission computed tomography, known as SPECT.

The FDM dual-extrusion approach fell short

SPECT is a nuclear medicine imaging method. It measures how a radioactive substance is distributed inside a patient. Spatial resolution limits how accurately the scanner maps the distribution. Research teams use anatomical phantoms to test and improve their imaging methods.

Early MSS phantoms used simple shapes like spheres. Those proved too basic to represent real anatomy. The team designed a brain phantom with detailed internal structures and complex overhangs. Their first build used fused deposition modelling with dual extrusion. Two problems surfaced. The spatial resolution of the printed parts was too low for the imaging work. The dual-extrusion process was not reliable enough to produce consistent phantoms.

Why SLS solved the spatial resolution problem

Selective laser sintering builds parts inside a bed of powder. Each layer sits on the surrounding material. No printed scaffolding is needed for overhangs. The overhang constraint was the issue breaking the FDM workflow. MSS researched the market and bought a Sinterit SLS printer to take over phantom production.

The Sinterit Lisa produced highly detailed prints with the reliability the research needed for 3D printed medical phantoms. The team prints each brain phantom in two halves. Doing it this way lets them clear loose powder from the internal cavities. They then bond the two halves together for testing.

“The print quality of the Lisa PRO is impressive,” says Walter Pucheanu, R&D Technician at the Institute for Multiscale Simulation.

For SPECT measurements, the phantom needs to hold a radioactive liquid without leaking. MSS coats the outer shell with epoxy resin to seal it. Pucheanu plans to switch the workflow to polypropylene powder. Polypropylene does not absorb liquid, so the resin step disappears entirely.

What this means for Australian universities and research labs

MSS bought a Lisa PRO when it was the right printer for the job. Sinterit has since replaced the Lisa PRO with the Sinterit Lisa X. The Lisa X is the current Sinterit flagship and the printer Australian research labs should evaluate today. It delivers a 13 litre build volume of 130 by 180 by 330 mm, a 30 W diode laser around six times faster than the Lisa PRO, layer heights from 75 to 175 microns, and a wider materials library covering eight production powders. The footprint stays compact enough for a university lab bench at 690 by 500 by 880 mm and 145 kg.

Australian universities running medical imaging, biomedical engineering, or materials research should mirror the MSS workflow for 3D printed medical phantoms. Start with a Sinterit Lisa X and Sinterit PA-12 Industrial powder. Move to Sinterit polypropylene powder for liquid-tight phantoms when the project requires it. The Sinterit Suzy is the compact entry point if budget or floor space is tight. For high-resolution anatomical work, the Sinterit Lisa X is the better match for 3D printed medical phantoms.

For broader context on SLS 3D printing for medical research beyond 3D printed medical phantoms, the ECA Medical case study shows the same Sinterit Lisa technology applied to commercial medical device development. The GoetheLab case study shows how a German university research centre runs Sinterit SLS across teaching and active research. For a deeper technical overview of the process behind 3D printed medical phantoms, see what is SLS 3D printing and the Sinterit Lisa X overview.

Frequently asked questions about 3D printed medical phantoms

• What is a 3D printed medical phantom? A 3D printed medical phantom is a physical model built to mimic the radiological properties of human tissue. Research labs use 3D printed medical phantoms to test scanner accuracy without exposing patients during scanner development.

• Why use SLS instead of FDM for 3D printed medical phantoms? SLS prints inside a powder bed, so complex overhangs and internal cavities do not need printed supports. FDM with dual extrusion failed on both spatial resolution and reliability for the MSS brain phantom. The lab moved to a Sinterit SLS workflow as the result.

• Which Sinterit printer is best for 3D printed medical phantoms today? The Sinterit Lisa X is the current Sinterit flagship for medical research. It has a 13 litre build volume and a faster 30 W diode laser than the Lisa PRO used in this MSS case study. The Sinterit Suzy is the compact alternative for smaller research budgets.

• Can polypropylene 3D printing be used for radiological phantoms? Yes. Sinterit polypropylene powder does not absorb liquid. Phantoms printed in polypropylene hold radioactive contrast media without a sealing step. This is the workflow Walter Pucheanu plans to adopt at MSS to remove the epoxy resin coating from the current process.

• What spatial resolution does the Sinterit Lisa X achieve for medical phantoms? The Sinterit Lisa X uses a galvanometer-driven diode laser to deliver high spatial resolution. The exact figure depends on the powder, layer height (75 to 175 microns), and part orientation. The printer is well matched to the medical phantom geometry which defeated the team's earlier FDM workflow.

---

Looking at SLS 3D printing for your university or research lab? View the Sinterit range at Australian 3D Printers or request a tailored quote.

Leave a comment

Leave a comment

Name*

Email*

Comment*

Send

• Share on:
• WhatsApp
• Deel
• X
• Pin it
• Messenger
• Email

---

Tags

3D Printer 3D Printers Education healthcare high spatial resolution Institute for Multiscale Simulation Learn medical imaging medical phantoms PA12 research Sinterit Sinterit Lisa X SLS 3D Printing