A Unified Platform and Quality Assurance Framework for 3D Ultrasound Reconstruction with Robotic, Optical, and Electromagnetic Tracking

Freehand 3D ultrasound (US) reconstruction promises volumetric imaging with the flexibility of standard 2D probes, yet existing tracking paradigms face a restrictive trilemma: marker-based systems demand prohibitive costs, inside-out methods require intrusive sensor attachment, and sensorless approaches suffer from severe cumulative drift. To overcome these limitations, we present MLRecon, a robust markerless 3D US reconstruction framework delivering drift-resilient 6D probe pose tracking using a single commodity RGB-D camera. Leveraging the generalization power of vision foundation models, our pipeline enables continuous markerless tracking of the probe, augmented by a vision-guided divergence detector that autonomously monitors tracking integrity and triggers failure recovery to ensure uninterrupted scanning. Crucially, we further propose a dual-stage pose refinement network that explicitly disentangles high-frequency jitter from low-frequency bias, effectively denoising the trajectory while maintaining the kinematic fidelity of operator maneuvers. Experiments demonstrate that MLRecon significantly outperforms competing sensorless and sensor-aided methods, achieving average position errors as low as 0.88 mm on complex trajectories and yielding high-quality 3D reconstructions with sub-millimeter mean surface accuracy. This establishes a new benchmark for low-cost, accessible volumetric US imaging in resource-limited clinical settings.

Freehand 3-D ultrasound (US) imaging has attracted increasing attention owing to its intuitive volumetric visualization, ease of use, and low cost. However, accurate 3-D reconstruction critically depends on stable probe pose estimation, yet existing trackerless methods remain susceptible to accumulated pose errors, particularly over long scanning trajectories. To address this limitation, we propose a global-to-local pose estimation framework that exploits external camera observations for globally stable localization and B-mode US images for anatomy-aware local refinement. Specifically, the framework comprises a dual-camera branch that performs contextual feature aggregation across camera views and temporal observations to estimate a globally consistent probe trajectory, and a B-mode branch that performs anatomical feature aggregation from sequential US images to capture tissue-dependent local motion cues. A cross-modal fusion module subsequently integrates the contextual camera features and anatomical US features to predict pose residuals and refine the camera-derived estimates in the transformation space. Furthermore, a multi-scale pose loss constrains relative motion over multiple temporal horizons to suppress accumulated drift during extended scans. The proposed framework is validated on phantom and in vivo datasets. On two in-house datasets (FUSION-J and FUSION-L) collected using different machines, the proposed US + Dual-Cam model reduces average trajectory drift to 1.67 mm and 1.29 mm, representing improvement of 16.50% and 27.12%, respectively, over a strong dual-camera baseline, while substantially outperforming US-only pose estimation (>13 mm drift). In in vivo forearm arteries reconstruction, it achieves Hausdorff distances of 1.58 mm, demonstrating the effectiveness of the proposed method on real clinical scenarios.

Robotic ultrasound (US) calibration is essential for accurately relating US images to the robot coordinate system, but accurate and automated calibration remains challenging because existing methods often require complex phantoms or external 3D trackers. In this work, we develop a tracker-free robotic US calibration framework using a spherical-marker phantom and a highly automated perception pipeline for sphere-center localization. The proposed threshold-free image-processing method localizes the spherical feature based on each US image's intensity distribution, eliminating hand-tuned intensity thresholds and improving robustness across imaging settings without per-system retuning. Multi-pose observations of the spherical fiducial are then used to estimate the US-to-EE transformation without external tracking or prior localization of the sphere center in the robot base frame. We validate the proposed framework on a robotic US platform through repeated sphere scans and further assess the calibrated system using geometrically distinct phantoms with known CAD models. Across 12 cross-validation folds, single-marker calibration achieved sphere-center accuracy and precision of $1.75\pm0.51$ mm and $0.85\pm0.11$ mm, respectively, compared with $1.72\pm0.51$ mm and $0.84\pm0.12$ mm for three-marker calibration. Across the three reconstruction sets, the single-marker calibration yielded pooled post-registration point-to-surface MAE$\pm$SD values of $0.41\pm0.35$ mm for the cone and $0.50\pm0.41$ mm for the triangular prism, closely matching the three-marker results of $0.40\pm0.35$ mm and $0.48\pm0.40$ mm, respectively.