Model-Guided Manufacturing of Transducer Arrays Based on Single-Fibre Piezocomposites

For breast cancer imaging, ultrasound computer tomography (USCT) is an emerging technology. To improve the image quality of our full 3-D system, a new transducer array system (TAS) design was previously proposed. This work presents a manufacturing approach which realises this new design. To monitor the transducer quality during production, the electro-mechanical impedance (EMI) was measured initially and after each assembly step. To evaluate the measured responses, an extended Krimholtz–Leedom–Matthaei (KLM) transducer model was used. The model aids in interpreting the measured responses and presents a useful tool for evaluating parasitic electric effects and attenuation at resonance. For quality control, the phase angle at thickness resonance φt was found to be the most specific EMI property. It can be used to verify the functionality of the piezocomposites and allows reliable detection of faults in the acoustic backing. Evaluating the final response of 68 transducers showed 5% variance of the series resonance frequency. This indicates good consistency of derived ultrasound performance parameters.