ABSTRACT
PURPOSE: To describe a digital fabrication method used for custom MRI receive coils with vacuum forming and electroless copper plating. METHODS: Our process produces intricate copper traces on curved surfaces. A three-dimensional scan of a desired anatomy is obtained and used to design coil elements. The layout is predistorted with a self built simulation of the vacuum forming process and the geometric overlaps are tested with electromagnetic simulation software. The desired coil geometry is patterned onto a polycarbonate sheet by sandblasting through a tape mask. The sandblasted areas are then catalyzed with a palladium-tin solution and vacuum formed. The catalyzed, three-dimensional part is placed into a custom built plating tank and copper plated. Electronic components are attached to the copper traces to form resonant receive coils. The methods described here are demonstrated and tested with an 8 channel visual cortex coil array. RESULTS: The prototype coils exhibit quality factor ratios higher than three, indicating body noise dominance. The coil array shows high signal-to-noise ratio (SNR) near the periphery of a head shaped phantom. In vivo images with up to 0 . 37 × 0 . 37 × 0 . 67 mm 3 $$ 0.37\times 0.37\times 0.67\;{\mathrm{mm}}^3 $$ spatial resolution were acquired on a human volunteer. CONCLUSION: This work presents the first example of vacuum formed coils with direct electroless copper plating. Our fabrication method results in coil arrays that are in close proximity to the body. This methods described here may enable the rapid development of a set of coils of different sizes for applications including longitudinal fMRI studies and MR-guided therapies.