Optimization of a novel large field of view distortion phantom for MR-only treatment planning

Purpose: MR-only treatment planning requires images of high geometric fidelity, particularly for large fields of view (FOV). However, the availability of large FOV distortion phantoms with analysis software is currently limited. This work sought to optimize a modular distortion phantom to accommodate multiple bore configurations and implement distortion characterization in a widely implementable solution. Method and Materials: To determine candidate materials, 1.0 T MR and CT images were acquired of twelve urethane foam samples of various densities and strengths. Samples were precision-machined to accommodate 6 mm diameter paintballs used as landmarks. Final material candidates were selected by balancing strength, machinability, weight, and cost. Bore sizes and minimum aperture width resulting from couch position were tabulated from the literature (14 systems, 5 vendors). Bore geometry and couch position were simulated using MATLAB to generate machine-specific models to optimize the phantom build. Previously developed software for distortion characterization was modified for several magnet geometries (1.0 T, 1.5 T, 3.0 T), compared against previously published 1.0 T results, and integrated into the 3D Slicer application platform. Results: All foam samples provided sufficient MR image contrast with paintball landmarks. Urethane foam (compressive strength ~1000 psi, density ~20 lb/ft³) was selected for its accurate machinability and weight characteristics. For smaller bores, a phantomversion with the following parameters was used: 15 foam plates, 55 9 55 9 37.5 cm³ (L9W9H), 5,082 landmarks, and weight ~30 kg. To accommodate > 70 cm wide bores, an extended build used 20 plates spanning 55 9 55 9 50 cm³ with 7,497 landmarks and weight ~44 kg.Distortion characterization softwarewas implemented as an externalmodule into 3DSlicer's plugin framework and results agreed with the literature. Conclusion: The design and implementation of a modular, extendable distortion phantom was optimized for several bore configurations. The phantom and analysis software will be available for multi-institutional collaborations and cross-validation trials to support MR-only planning.