Preparation of the PZT transducers. Bulk PZT discs were purchased from American Piezo (APC − 850). To enable access to top and bottom electrodes from the same plane, discs were modified to a custom wrap-around electrode configuration. A commercial picosecond-pulsed laser ablation system (Supplementary Fig. 6; 500 kHz pulse repetition frequency with a divider of 3, 1.5 W power and 1500 mm s − 1 laser cutting speed, R4, LPKF Laser & Electronics) was utilized to isolate a small portion of the silver electrode on one face of the PZT disc. Then, the isolated portion of the silver electrode on that face was electrically connected to the electrode on the opposite face of the disc using a low temperature silver paste (PE827, DuPont).
Fabrication of the flexible ultrasonic transducers. 25 µm thick flexible laminate with 9 µm copper layer (AC0925, DuPont) was patterned with LPKF U4 to create the circuit pattern of the transducers and cut the laminate for air-backing. Two-component epoxy resin (EPOTEK 301-2FL, 1:0.35) was mixed at 3500 rpm for 20 minutes using a speed mixer (Hauschild mixer, DAC 150). Al2O3 nanoparticles (290nm, Nanografi) were added to the mixture for desired acoustic impedance and mixed at 3500 rpm for another 10 minutes using the same speed mixer. The epoxy-nanoparticle mixture was poured inside a disc shaped PDMS (Dow Corning, 10:1) mold. Cured matching layer was manually bonded to PZT discs using a fast curing two-component epoxy (Loctite EA3 422, 1:1). PZT discs with matching layers were manually placed and reflowed with low-temperature solder paste (TS391LT, Chip Quik) (Supplementary Figs. 7 and 8).
Matching layer thickness optimization. After identifying the matching layer composition with desired density and speed of sound (Supplementary Fig. 9), LPKF R4 was utilized (300 kHz pulse repetition frequency with a divider of 2, 7.3 W power and 1400 mm s − 1 laser cutting speed) to thin the matching layer into desired thickness. Laser parameters were optimized to remove a micrometer of matching layer in each pass. After each material removal step, conductance measurements were performed (MFIA Impedance Analyzer, Rohde & Schwarz) in deionized water to find the optimum matching layer thickness. Laser etching followed by admittance measurement procedure was repeated until the broadest conductance measurement was obtained.
Packaging. To preserve the air-backed design of the transducers, laminate under the disc-shaped PZTs were cut. In analogous fashion, a double-sided tape (Tesa 64621) was machined. PZT-soldered laminate was adhered to the bottom encapsulation layer (40 µm thick PET sheet) using the double-sided tape. For the front side encapsulation, a mold was 3D printed (BMF microArch S230) and parylene-c coated (Plasma Parylene Systems). The laminate with transducers were placed inside the mold. Silicone encapsulant (PDMS, 10:1) was poured and cured at 60°C for 9 hours. To enable gel-free measurements, Silbione 4717 gel (1:1) was screen-printed on the front side of the transducers (Supplementary Figs. 10 and 11).
Characterization of the transducers. All electrical and acoustics characterizations were conducted in deionized water. An impedance analyzer (MFIA, Zurich Instruments) was employed to obtain frequency dependent electrical parameters (electrical impedance, phase, conductance) of the transducer. For the pulse-echo response, an arbitrary waveform generator (33521B Waveform Generator, Keysight) was used to excite the transducer-under-test. The echo signal from a stainless steel reflector was received by an osciloscope (Picoscope 6000 series) through the use of a diplexer (RDX-6, RITEC Inc.) (Supplementary Fig. 12).
Underwater characterizations were conducted inside an UMS Research system covered with acoustic absorbers (AptFlex F28, Precision Acoustics). The pressure field, sound pressure output and bandwidth were evaluated with a 0.5 mm needle hydrophone (Precision Acoustics) connected to an oscilloscope (DSOX3024G, Keysight Technologies).
Electronics system design and fabrication. Modeling and simulation of the UBVM hardware were performed in LTSpice (Supplementary Fig. Y8). Following the simulations, all components were purchased from Digikey Electronics. Double-sided printed circuit board fabrication started with drilling via holes on copper-clad laminates as per design (LPKF Protomat E44). Drilling step was followed up by pulsed direct current electroplating of copper to connect the top and bottom layers through drilled holes (LPKF Contac S4). Both sides were then patterned using LPKF U4. As shown in Supplementary Fig. 20, main components include a Bluetooth Low Energy integrated microcontroller (STM32WB55RG, STMicroelectronics), a single and a dual channel multiplexer (DG408 and DG409, Maxim Integrated), a high voltage pulser (MAX14808, Maxim Integrated), an operational amplifier (OPA357, Texas Instruments) and a comparator (MAX941, Maxim Integrated) (Supplementary Fig. 13–20).
Transmit Phase. During the transmit phase, the microcontroller generates two sets of five 2 MHz pulses amplitude of 3.3V every 2,5 seconds (Supplementary Fig. 21). The two sets have a 180° phase difference and are required by the pulser IC for bipolar pulse generation. Through the use of the multiplexer, four individual input channels of the high-voltage pulser are switched at 10-second intervals. Ultrasonic transducers are then excited by bipolar pulses as per the input excitation signals and high voltage DC supply level of the pulser (Supplementary Fig. 22).
Receive Phase. The MAX14808 high-voltage pulser includes a transmit/receive switch, which forwards the received signal from bladder walls to the receive circuitry. The op-amp provides a gain of 10 with 1k and 10k resistors, followed by an RC low-pass filter with a -3 dB cut-off frequency of 5.88 MHz to eliminate the higher order harmonics in the received signal caused by the gain bandwidth product of the amplifiers of the amplifiers. The amplified signal is then fed to the comparator, which is used as a threshold detector. If the received and amplified signal surpasses the comparator threshold (e.g. when an echo is received) the comparator output goes high (5 V). Otherwise, the comparator output is low (0 V) (Supplementary Fig. 23). To block false firings at the output, comparator threshold is dynamically varied through the use of a simple resistive network composed of two 20k resistors that is series between the supply and the ground, the divided voltage then fed back to the comparator’s positive pin over a 60k resistor. The ratio of these resistors determines the amount of the hysteresis.
Data Acquisition and Bluetooth Operation. Proposed one-bit analog to digital conversion allows the use of the input capture mode of the microcontroller. More specifically, a timer channel of the microcontroller is configured to capture the value of a counter at the moment the input signal transitions from one state to another. By connecting the timer channel to the comparator output, time-stamps of the echo signals are detected and stored by the microcontroller through the use of direct memory access (DMA). This storage process provides fast capturing of the incoming data without interrupting the work of the microcontroller. Subsequently, this data is transmitted via Bluetooth Low Energy consisting of a Generic Attribute Profile (GATT) server that includes custom services and characteristics. In the context of capturing echo timestamps, one service that contains a data capturing parameter as a characteristic and transfers the data over BLE was used. This characteristic can be accessed by other BLE devices, allowing them to read, write, or be notified. The data send over BLE is then passed through a custom application on a mobile phone for further processing in Amazon Web Services (AWS). The phone between the wireless microcontroller and AWS behaves as a gateway for conveying the data using the Internet. The data processing stages involved in AWS allow for the transmission of bladder volume information to the phone, passing through the following services: AWS IoT, AWS Kinesis Data Firehose, AWS S3 Bucket, AWS Lambda, AWS AppSync, AWS Dynamo Table, and finally, the user application. GraphQL language is employed in this pipeline to facilitate interaction between users and the services involved. Users can utilize GraphQL's capabilities to perform operations such as reading and writing data, as well as connecting their smartphones to the pipeline through an Application Programming Interface (API).
Cloud Data Processing. The timestamps captured by the microcontroller are processed in AWS Lambda service using Python. Each timestamp arriving at AWS Lambda triggers the Python code. Therefore, the algorithm continuously registers the timestamps into the data array and checks if the monitoring is complete based on the transducer number information attached to the timestamps. Once the transducer number changes from 4 to 1, the algorithm understands that the monitoring is complete and starts processing the collected data to approximate the bladder volume. First, the timestamp array is masked to determine the number of data points that can be used in the volume calculation. Since a sphere can be defined by a minimum of 4 points, if there is insufficient number of data points in the array, the algorithm sends an error message to the mobile app. Otherwise, the processing continues with the averaging step. Timestamps for anterior and posterior signals of each transducer are averaged and registered to a new array. Then timestamps in the averaged data array are converted to coordinates assuming a speed of sound of 1480 m/s50. Finally, the coordinate array is fed into the sphere fitting function, which finds the volume of the best-fit sphere using least squares method that utilizes the Broyden-Fletcher-Goldfarb-Shanno (BFGS) minimization algorithm.
In vitro characterization. The stainless-steel reflector and round bottom flasks in different volumes were used to evaluate the performance of the developed system in vitro. To test the capabilities of our electronics and firmware, the pulse-echo experiments were conducted at different frequencies. The stainless-steel reflector was attached to a motorized stage of the UMS Research system. Commercial ultrasonics transducers with various operating frequencies (1-2-3-5-8 MHz) were submerged into UMS Research system and were connected to the developed electronics. The transducers were excited, and the received echoes were captured by our electronics. Captured echo timestamps were then transferred to a mobile phone.
To mimic our in-vivo application, two round bottom flasks were submerged into UMS Research system, along with our transducers. A flex cable was used to connect the transducers to the PCB outside the water tank. Received timestamps were transferred to a mobile phone and converted into coordinate points and fitted to a spherical shape. After the calculations, the volume data of the flask-under-test was displayed.
In vivo measurements. Continuous bladder volume measurement was carried out on five healthy volunteers with an approved protocol by Koc University Ethics Committee (2023.006.IRB2.004). The UBVM device was placed on the lower abdomen just above the pubic bone for the measurements. For comparison with clinical ultrasound imaging, the volunteers were examined in supine position with Toshiba Nemio 10 scanner equipped with a 3.5 MHz convex array transducer by an experienced urologist. Bladder images representing the maximum longitudinal, transverse and anterior-posterior diameters were recorded. The diameter dimension were determined by manually placing the calipers on the recorded images. Based on the measured dimensions, spherical volume formula with a correction coefficient of 0.52 was used to calculate the bladder volume51.