Processing and Modeling of Alginate Hydrogel for Radiologically-Equivalent Biomedical Phantoms.

The foaming of hydrogels presents a promising strategy for tailoring mechanical and radiological properties to replicate biological soft tissues for biomedical phantom applications. A computational fluid dynamics (CFD) framework is developed to predict void fraction distribution in alginate hydrogel precursor solutions aerated by air injection through a bottom nozzle. The objective is to use the framework for the design of the foaming system to match the desired gas-fraction distribution and radiological property. Seven parametric cases are investigated, varying inlet air velocity, alginate concentration, and surface tension. Results show that higher inlet velocities promote stronger jet penetration and greater gas accumulation, while increasing alginate concentration confines the bubble plume, with quasi-steady gas fractions displaying a non-monotonic trend with concentration. Elevated surface tension yields broader plume coverage and improved gas distribution uniformity at the expense of peak void fraction. The predicted void fractions map to Hounsfield Unit (HU) values of -34 to -103, corresponding to adipose and fatty breast tissue attenuation (-50 to -150 HU). The peak gas fraction at 5.0 wt% alginate yields -307 HU, approaching published experimental CT measurements for the same formulation (-460 to -233 HU).