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Spectral radiography and fluoroscopy with multi-layer flat-panel detectors (FPD) is being actively investigated in a range of clinical applications. For applications involving contrast administration, maximal contrast resolution is achieved when overlaying background anatomy is completely removed. This calls for three-material decomposition (soft tissue, bone, and contrast) enabled by measurements in three energy channels. We have previously demonstrated the feasibility of such decomposition using a triple-layer detector. While algorithmic solutions can be adopted to mitigate noise in the material basis images, in this work, we seek to fundamentally improve the conditioning of the problem through optimized system design. Design parameters include source voltage, the thickness of the top two CsI scintillators, and the thickness of two copper interstitial filters. The design objective is to minimize noise in the basis image containing contrast, chosen as gadolinium in this work to improve separation from bone. The optimized design was compared with other designs with unoptimized scintillator thickness and/or without interstitial filtration. Results show that CsI thickness optimization and interstitial filtration can significantly reduce noise in the gadolinium image by 35.7% and 42.7% respectively within a lung ROI, which in turn boosts detectability of small vessels. Gadolinium and bone signals are separated in all cases. Visualization of coronary vessels is enabled by the combining optimized system design and regularization. Results from this work demonstrate that three-material decomposition can be significantly improved with system design optimization. Optimized designs obtained from this work can inform imaging techniques selection and triple-layer detector fabrication for spectral radiography.
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