Monolithic Wideband Air-Coupled Ultrasonic Transducer Based on Additively Manufactured Ferroelectrets

Air-coupled ultrasonic transducers are widely used in non-destructive testing, acoustical sonar systems, and biomedical imaging. These applications require transducers that operate effectively across a broad acoustic frequency spectrum, offer adaptable geometric designs, and increasingly incorporate eco-friendly materials. In this work, we present a monolithic, 3D-printed air-coupled ultrasonic transducer based on ferroelectrets (FEs) and fabricated from biocompatible polylactic acid (PLA). We evaluated the transducer’s acoustical performance by measuring the surface velocity of its active area using laser Doppler vibrometry and assessed its robustness during continuous operation over a 19-day period. Additionally, we measured the sound pressure level (SPL) and wideband characteristics in an anechoic chamber across excitation frequencies from 1kHz to 100kHz. At a resonance frequency of 33kHz, our transducer achieved an SPL of 94.3dB and surface velocities up to 37mm/s. The measured bandwidth of 65.2kHz at the -6dB threshold corresponds to a fractional bandwidth of 189%. The observed exponential decay of the surface velocity, stabilizing at 15% of its initial amplitude, aligns with the isothermal surface potential decay typically observed in FE films made from PLA. These results demonstrate the effectiveness of the transducer, which features an adaptable backplate for tuning acoustic properties. The low-cost transducer, manufactured from biocompatible PLA, is particularly suited for imaging and biomedical applications furthering green electronics.