Investigation of synthetic aperture methods in ultrasound surface imaging using elementary surface types

Three high precision metallic samples of known geometries (cuboid, sphere and cylinder) which featured a range of elementary surface primitives were imaged using a 5 MHz, 128 element 1D phased array employing both SAFT and TFM approaches. The array was manipulated around the samples using a precision robotic positioning system, allowing for repeatable ultrasound derived 3D surface point clouds to be created. A global thresholding technique was then developed that allowed the extraction of the surface profiles, and these were compared with the known geometry samples to provide a quantitative measure of error of 3D surface reconstruction. The mean errors achieved with optimised SAFT imaging for the cuboidal, spherical and cylindrical samples were 1.3 mm, 2.9 mm and 2.0 mm respectively, while those for TFM imaging were 3.7 mm, 3.0 mm and 3.1 mm, respectively. These results were contrary to expectations given the higher information content associated with the TFM images. However, it was established that the reduced error associated with the SAFT technique was associated with significant reductions in side lobe levels of approximately 24 dB in comparison to TFM imaging, although this came at the expense of reduced resolution and coverage.