Automated Design of Patient-Specific 4D-Printed Phantoms for Quality Assurance of Adaptive Radiotherapy on a 1.5T MR-Linac

Background: Independent end-to-end verification of adaptive radiotherapy on MR-Linac systems is limited by the lack of patient-specific phantoms able to reproduce imaging and dosimetric properties from CT and MRI scanners. We present a method for automated generation of 4D, patient-specific, multi-material 3D-printable phantoms for quality assurance of adaptive radiotherapy on a 1.5T MR-Linac. Methods: Patient images were automatically segmented using a pretrained deep learning model. The segmented structures were converted into high-resolution 3D meshes and assembled into printable phantoms. A dosimeter holder was inserted at user-defined anatomical locations, with orientation optimized to avoid traversal across heterogeneous tissue interfaces. Physiological motion was incorporated by generating phantoms from images at different timepoints and interpolating deformation fields to create continuous 4D models. Multi-material organs designed by mixing a set of six polymers at various proportions were used to reproduce tissue-specific imaging properties. The properties of material mixtures were evaluated in a clinical CT simulator and a 1.5T MR-Linac. Results: The proposed workflow enables automated generation of anatomically realistic phantoms with several types of embedded dosimeters. A discrete search method was designed for placement and immobilization of OSLD, film, and ion chamber dosimeters. Calibration curves for Hounsfield units were derived through variations in radiopaque material content, while MR signal intensity was modulated by gel and tissue matrix mixtures. Patient-derived abdominal phantoms were fabricated at multiple scales while replicating internal anatomical detail. Multi-dimensional phantom generation enabled continuous representation of motion states with consistent mesh topology across phases. Conclusions: We demonstrate an end-to-end workflow for automated generation of 4D patient-specific phantoms for MR-Linac quality assurance. The method combines realistic anatomy, embedded dosimetry, multimodal imaging properties, and physiological motion within a single fabrication framework. This approachmay enable an improved validation of adaptive radiotherapy workflows in MR-guided treatment devices.