The Effects of Manufacturing Errors on the Performance of Acoustic Metamaterial Lenses Operating in the MHz Regime

This article explores the use of acoustical metamaterials to design lenses in the megahertz frequency range of relevance to applications in nondestructive testing and medical imaging. In particular, the effect of manufacturing errors on their focusing performance is quantified. A rapid method for including manufacturing errors is described and this is used to perform Monte Carlo simulations of wave pressure fields from lenses with manufacturing errors. In this process, the required time delay distribution for a target focal length is calculated and the acoustical lenses with a chosen unit cell type are designed. Manufacturing errors of the unit cells are then added, considering their statistical properties and a large number of realizations. As an example, an acoustical lens with a focal length of 76 mm at a frequency of 1 MHz is designed using three different unit cell types: steel cross unit cell, resin circular void unit cell, and silicone-resin layered unit cell. Finally, the resulting acoustic pressure fields are computed using a Huygens' principle model to assess the effects of manufacturing errors on lens performance, i.e., the focal length and the size of the focal spot. It is shown that the performance of lenses consisting of silicone-resin layered units is less affected by the manufacturing errors than for lenses constructed with the other unit cells. This study paves the way for selecting a suitable combination of metamaterial unit cell and manufacturing method to enable acceptable lens imaging performance.