Optimal Design of Sandwich Composite Cradle for Computed Tomography Instrument by Analyzing the Structural Performance and X-ray Transmission Rate

Abstract

Carbon fiber-reinforced composite has an excellent X-ray transmission rate as well as specific modulus and strength. The major components of medical devices, X-ray systems, and computed tomography (CT) equipment that require superior X-ray transmission performance also require structural performance for deformation. Therefore, medical components consist of a sandwich composite structure with carbon fiber composites applied as a face material. The X-ray transmission ratios of face material and foam material were measured according to thickness, and the relation equation for thickness and X-ray transmission rate was derived. The X-ray transmission rate for the sandwich composite structure consisting of face and core material was measured and the relationship between the X-ray transmission rate and the dimension for thickness of sandwich cradle was derived. Using the optimization process, the thicknesses of face and core materials for sandwich cradles were determined to minimize the cost of used materials. They also met the criteria that the deflection should not be more than 20 mm, and the X-ray transmission rate of the cradle should be equal to or greater than that of aluminum at 1.5 mm thickness. The sequence pattern of face material was proposed through structural analysis. The face material of the sandwich cradle was manufactured by a resin infusion and vacuum bagging method, followed by inserting the core between the cured faces. Next, the sandwich cradle assembly was completed and re-cured. The sandwich cradle met the criteria that the deflection at the end was 19.04 mm and the X-ray transmission was 78.7% greater than the X-ray transmission of 1.5 mm aluminum.