Ultrasound Sensors at Scale: Disposable, Low-cost, and High-performance

Ultrasound imaging will soon be taking a very sizable step forward in terms of innovative applications. Polymer-based capacitive micromachined ultrasound transducers (polyCMUT) are enabling this transformative stage, offering a more hygienic transducer at a much lower cost. Ultrasound is an excellent tool in the diagnosis of many common pathologies, and the disposable polyCMUT transducer is ideal for minimizing viral contamination and interpatient infection. From cardiovascular monitoring, musculoskeletal imaging, obstetrics, or therapeutic applications, Sonus Array Technology (SAT) is opening doors to new frontiers in medical imaging.  

Applications

The advantages of polyCMUTs over traditional ultrasound technologies begin with flexible polymers. Polymers are inexpensive and easy to process, with literally hundreds of polymers as potential candidates. Many of those are also bio-compatible, allowing for long-term use in medical applications.

PolyCMUTs can be mass produced using scalable techniques, making them a cost-effective solution for clinical use, while ensuring excellent performance and accessibility. PolyCMUTs can be fabricated on various flexible and semi-flexible substrates, such as polyimide, making them easier to integrate with existing electronics. The flexible ultrasound sensor conforms to the body, which means less reliance on coupling gel, and improved image resolution.  

Conformal ultrasound sensors enable long-term continuous monitoring, which is especially relevant in cardiovascular care where real-time imaging of heart function is crucial.

Multiple sensors can be deployed individually and scanned in parallel by a single unit: all scans can integrate through the single, shared backend, made possible by low cost transducers. This is especially key for some ultrasound technologies whose platform provides direct visualization of cardiac filling and function over time that allows for informed analysis, and a time-sensitive diagnosis for critically ill patients. 

For outpatient and in-home care, polyCMUT ultrasound monitoring becomes a patient-friendly option offering scalable diagnostics without capital-intensive probes, efficiently providing patients and their caregivers real-time insights into their health and bypassing the need for frequent hospital visits.

PolyCMUT sensors are ideal in endoscopic ultrasound procedures as well. Providing ease of use, sterility, and real-time diagnostic assessment, they can offer more precise imaging of the gastrointestinal tract and surrounding organs such as the pancreas, liver and gallbladder. 

The disinfection of reusable ultrasound probes is prone to variability, delay, and human error. Studies show that only 15–47% of users disinfect equipment components like cords and keyboards properly [ref].

In critical ICU, ER and OR environments, the sterile, single-use probes minimize the risk of infection. Soft, disposable sensors ensure patient-sensitive neonatal and pediatric care with the flexibility necessary to conform to space-limited curvilinear surfaces. 

Form factor versatility supports a broad range of highly customizable options in medical applications. They could range from patches and catheters to wearables and embedded transducers. 

Conclusion

At Sonus Microsystems, we’re revolutionizing how ultrasound is used: When one sonographer, and one backend unit, can achieve multi-sensor, multi-patient data acquisition that results in lower costs, higher imaging quality and dramatically improved accessibility in underserved communities with limited diagnostic infrastructure. 

Innovation opens new doors and brings the future into focus. At Sonus, its impact on medical imaging is a constant, and rewarding effort.