Design, Fabrication, and Testing of a Flexible Three-Dimensional Printed Percutaneous Needle With Embedded Actuators

Abstract Percutaneous needle-based procedures have replaced open surgeries in cancer treatments to perform the tasks with minimal invasiveness to the tissue. Precise placement of the needle at target positions in cancer diagnostic (e.g., breast biopsy) or therapeutic (e.g., prostate brachytherapy) procedures governs the success of such procedures. Also, in many needle insertion applications, it is desired to steer away from critical organs or to maneuver around anatomical obstacles in tissue. This work introduces a flexible three-dimensional (3D) printed percutaneous needle with embedded actuators for improved navigation inside the tissue toward the target. The needle is manipulated via a programmed portable motorized control unit to realize an average angular deflection of about 15 and 14 deg in air and a tissue-mimicking phantom, respectively. We demonstrated the needle's capability to reach the target, while avoiding obstacles. We also demonstrated that the flexible needle can be guided through a desired trajectory by controlling its angular deflection and axial movement. The 3D deflection of the needle is expected to assist in breast cancer lumpectomy for multiple extractions of tissue samples or in prostate brachytherapy via a curvilinear approach. The flexible needle may help reducing the complexity of current path planning algorithms, and thereby improve efficiency of closed-loop control systems in needle steering.