To propose comprehensive characterization methods of additive manufacturing (AM) materials for MV photon and MeV electron radiotherapy. This study investigated 15 AM materials using CT machines. Geometrical accuracy, tissue-equivalence, uniformity, and fabrication parameters were considered. Selected soft tissue equivalent filaments were used to fabricate slab phantoms and compared with water equivalent RW3 phantom by delivering planar 6 & 10 MV photons and 6, 9, 12, 15, & 18MeV electrons. Finally, a 3D printed CT-Electron Density characterization phantom was fabricated. Materials used to print test objects can simulate tissues from adipose (relative electron density, ρe=0.72) up to near inner bone-equivalent (ρe=1.08). Lower densities such as breast and lung can be simulated using infills from 90% down to 30%, respectively. The gyroid infill pattern shows the lowest CT number variation and is recommended for low infill percentage printing. CT number uniformity can be observed from 40% up to 100% infill, while printing orientation does not significantly affect the CT number. The measured doses using the 3D printed phantoms show to have good agreement with TPS calculated dose for photon (< 1% difference) and electron (< 5% difference). Varying the printed slab thicknesses shows very similar response (< 3% difference) compared with RW3 slabs except for 6MeV electrons. Lastly, the fabricated CT-ED phantom generally matches the lung- up to the soft tissue- equivalence. The proposed methods give the outline for characterization of AM materials as tissue-equivalent substitute. Printing parameters affect the radiological quality of 3D-printed object.
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