Efficiently building receive arrays with electromagnetic simulations and additive manufacturing: A two-layer, 32-channel prototype for 7T brain MRI

Purpose We propose a comprehensive workflow to design and build fully customized dense receive arrays for MRI, providing prediction of SNR and g-factor. Combined with additive manufacturing, this method allows an efficient implementation for any arbitrary loop configuration. To demonstrate the methodology, an innovative two-layer, 32-channel receive array is proposed.Methods The design workflow is based on numerical simulations using a commercial 3D electromagnetic software associated with circuit model co-simulations to provide the most accurate results in an efficient time. A model to compute the noise covariance matrix from circuit model scattering parameters is proposed. A 32-channel receive array at 7 T is simulated and fabricated with a two-layer design made of non-geometrically decoupled loops. Decoupling between loops is achieved using home-built direct high-impedance preamplifiers. The loops are 3D-printed with a new additive manufacturing technique to speed up integration while preserving the detailed geometry as simulated. The SNR and parallel-imaging performances of the proposed design are compared with a commercial coil, and in vivo images are acquired.Results The comparison of SNR and g-factors showed a good agreement between simulations and measurements. Experimental values are comparable with the ones measured on the commercial coil. Preliminary in vivo images also ensured the absence of any unexpected artifacts.Conclusion A new design and performance analysis workflow is proposed and tested with a non-conventional 32-channel prototype at 7 T. Additive manufacturing of dense arrays of loops for brain imaging at ultrahigh field is validated for clinical use.