  The goal of this work was to build an anthropomorphic thorax phantom capable
of breathing motion with materials mimicking human tissues in x-ray imaging
applications. The thorax phantom, named Casper, was composed of resin (body),
foam (lungs), glow polyactic acid (bones) and natural polyactic acid (tumours
placed in the lungs). X-ray attenuation properties of all materials prior to
manufacturing were evaluated by means of photon-counting computed tomography
(CT) imaging on a table-top system. Breathing motion was achieved by a
scotch-yoke mechanism with diaphragm motion frequencies of 10 - 20 rpm and
displacements of 1 to 2 cm. Casper was manufactured by means of 3D printing of
moulds and ribs and assembled in a complex process. The final phantom was then
scanned using a clinical CT scanner to evaluate material CT numbers and the
extent of tumour motion. Casper CT numbers were close to human CT numbers for
soft tissue (46 HU), ribs (125 HU), lungs (-840 HU) and tumours (-45 HU). For a
2 cm diaphragm displacement the largest tumour displacement was 0.7 cm. The
five tumour volumes were accurately assessed in the static CT images with a
mean absolute error of 4.3%. Tumour sizes were either underestimated for
smaller tumours or overestimated for larger tumours in dynamic CT images due to
motion blurring with a mean absolute difference from true volumes of 10.3%.
