Creating a Physical Sheep Head Surrogate from a Segmented CT Scan

Report Number:
ARL-TR-10275

Publish Date:

January 21, 2026

Distribution:

Approved for public release: distribution is unlimited.


Author(s):

Christopher G. Sinks, Ian M. Berke, Brian Fagan, W. David Hairston, Louis J. Dankovich IV, and Erika Matheis

Abstract:

Testing on live biological systems involves many processes and uncontrolled variables that can incur high costs and introduce undesired complexity into experimentation. Here, we develop a surrogate head device that allows for bench-level testing of bio-similar materials to reduce the need for live-animal experimentation. We take a segmented scan from a Dorper sheep and, through a combination of hydrogel chemistry and 3-D printing, create a multilayer head with embedded sensors to help confirm computational simulations of various conditions. While we still require significant iteration to fully reproduce every tissue type and geometry, we have created a base surrogate that has successfully been used in testing.

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