Characterisation of 3D-printable thermoplastics to be used as tissue-equivalent materials in photon and proton beam radiotherapy end-to-end quality assurance devices

<i>Objective.</i>To investigate the potential of 3D-printable thermoplastics as tissue-equivalent materials to be used in multimodal radiotherapy end-to-end quality assurance (QA) devices.<i>Approach.</i>Six thermoplastics were investigated: Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate Glycol (PETG), Polymethyl Methacrylate (PMMA), High Impact Polystyrene (HIPS) and StoneFil. Measurements of mass density (ρ), Relative Electron Density (RED), in a nominal 6 MV photon beam, and Relative Stopping Power (RSP), in a 210 MeV proton pencil-beam, were performed. Average Hounsfield Units (HU) were derived from CTs acquired with two independent scanners. The calibration curves of both scanners were used to predict averageρ,RED and RSP values and compared against the experimental data. Finally, measured data ofρ,RED and RSP was compared against theoretical values estimated for the thermoplastic materials and biological tissues.<i>Main results.</i>Overall, goodρand RSP CT predictions were made; only PMMA and PETG showed differences >5%. The differences between experimental and CT predicted RED values were also <5% for PLA, ABS, PETG and PMMA; for HIPS and StoneFil higher differences were found (6.94% and 9.42/15.34%, respectively). Small HU variations were obtained in the CTs for all materials indicating good uniform density distribution in the samples production. ABS, PLA, PETG and PMMA showed potential equivalency for a variety of soft tissues (adipose tissue, skeletal muscle, brain and lung tissues, differences within 0.19%-8.35% for all properties). StoneFil was the closest substitute to bone, but differences were >10%. Theoretical calculations of all properties agreed with experimental values within 5% difference for most thermoplastics.<i>Significance.</i>Several 3D-printed thermoplastics were promising tissue-equivalent materials to be used in devices for end-to-end multimodal radiotherapy QA and may not require corrections in treatment planning systems' dose calculations. Theoretical calculations showed promise in identifying thermoplastics matching target biological tissues before experiments are performed.