Purpose: The purpose is to design and validate an anthropomorphic polyvinyl alcohol (PVA) liver phantom with respiratory motion to simulate needle-based interventions. Such a system can, for example, be used as a validation tool for novel needles. Methods: Image segmentations of CT scans of four patients during inspiration and expiration were used to measure liver and rib displacement. An anthropomorphic liver mold based on a CT scan was 3D printed and filled with 5% w/w PVA-to-water, undergoing two freeze–thaw cycles, in addition to a 3D-printed compliant rib cage. They were both held in place by a PVA abdominal phantom. A sinusoidal motion vector, based on the measured liver displacement, was applied to the liver phantom by means of a motion stage. Liver, rib cage and needle deflection were tracked by placing electromagnetic sensors on the phantom. Liver and rib cage phantom motion was validated by comparison with the CT images of the patients, whereas needle deflection was compared with the literature. Results: CT analysis showed that from the state of expiration to inspiration, the livers moved predominantly toward the right (mean: 2 mm, range: − 11 to 11 mm), anterior (mean: 15 mm, range: 9–21 mm) and caudal (mean: 16 mm, range: 6–24 mm) direction. The mechatronic design of the liver phantom gives the freedom to set direction and amplitude of the motion and was able to mimic the direction of liver motion of one patient. Needle deflection inside the phantom increased from 1.6 to 3.8 mm from the initial expiration state to inspiration. Conclusions: The developed liver phantom allows for applying different motion patterns and shapes/sizes and thus allows for patient-specific simulation of needle-based interventions. Moreover, it is able to mimic appropriate respiratory motion and needle deflection as observed in patients.

Steering of needles involves the planning and timely modifying of instrument-tissue force interactions to allow for controlled deflections during the insertion in tissue. In this work, the effect of tip shape on these forces was studied using 10 mm diameter needle tips. Six different tips were selected, including beveled and conical versions, with or without pre-bend or pre-curve. A six-degree-of-freedom force/torque sensor measured the loads during indentations in tissue simulants. The increased insertion (axial) and bending (radial) forces with insertion depth-the force-displacement slopes-were analyzed. Results showed that the ratio between radial and axial forces was not always proportional. This means that the tip load does not have a constant orientation, as is often assumed in mechanics-based steering models. For all tip types, the tip-load assumed a more radial orientation with increased axial load. This effect was larger for straight tips than for pre-bent or pre-curved tips. In addition, the force-displacement slopes were consistently higher for (1) increased tip angles, and for (2) beveled tips compared to conical tips. Needles with a bent or curved tip allow for an increased bending force and a decreased variability of the tip load vector orientation.

Medical phantoms can be used to study needle-tissue interaction and to train medical residents. The purpose of this research is to study the suitability of polyvinyl alcohol (PVA) as a liver tissue mimicking material in terms of needle-tissue interaction. Insertions into ex-vivo human livers were used for reference. Six PVA samples were created by varying the mass percentage of PVA to water (4 m% and 7 m%) and the number of freeze-thaw cycles (1, 2 and 3 cycles, 16 hours of freezing at −19 °C, 8 hours of thawing). The inner needle of an 18 Gauge trocar needle with triangular tip was inserted 13 times into each of the samples, using an insertion velocity of 5 mm/s. In addition, 39 insertions were performed in two ex-vivo human livers. Axial forces on the needle were captured during insertion and retraction and characterized by friction along the needle shaft, peak forces, and number of peak forces per unit length. The concentration of PVA and the number of freeze-thaw cycles both influenced the mechanical interaction between needle and specimen. Insertions into 4 m% PVA phantoms with 2 freeze-thaw cycles were comparable to human liver in terms of estimated friction along the needle shaft and the number of peak forces. Therefore, these phantoms are considered to be suitable liver mimicking materials for image-guided needle interventions. The mechanical properties of PVA hydrogels can be influenced in a controlled manner by varying the concentration of PVA and the number of freeze-thaw cycles, to mimic liver tissue characteristics.