The fabrication and integration of a 15 MHz array within a biopsy needle

It is proposed that integrating ultrasound transducer arrays at the tip of tools such as biopsy needles could enable valuable, real-time image feedback during interventional procedures. High-resolution ultrasound imaging has the potential to aid navigation of interventional tools, and to assist diagnosis or treatment via in-vivo tissue characterisation in the breast, amongst many other applications. In order to produce miniature transducer arrays incorporated within biopsy needle-sized packages (2–5 mm diameter), the challenges in micromachining and handling transducer materials at this scale must be overcome. This paper presents fabrication processes used in the micromachining of a 16 element 15 MHz PIN-PMN-PT piezocrystal-polymer composite array and its integration into an 11 G breast biopsy needle. Particular emphasis is given to the manufacturing of the 1–3 dice-and-fill piezocrystal composite, and establishing electrical interconnects. Characterisation measurements have demonstrated operation of each of the 16 elements within the needle case.