Airborne 3D imaging using ultrasound is a promising sensing modality for robotic applications in harsh environments. Over the last decade, several high-performance systems have been proposed in the literature. Most of these sensors use a reduced aperture microphone array, leading to artifacts in the resulting acoustic images. This paper presents a novel in-air ultrasound sensor that incorporates 1024 microphones, in a 32-by- 32 uniform rectangular array, in combination with a distributed embedded hardware design to perform the data acquisition. Using a broadband Minimum Variance Distortionless Response (MVDR) beamformer with Forward-Backward Spatial Smoothing (FB-SS), the sensor is able to create both 2D and 3D ultrasound images of the full-frontal hemisphere with high angular accuracy with up to 70dB main lobe to side lobe ratio. This paper describes both the hardware infrastructure needed to obtain such highly detailed acoustical images, as well as the signal processing chain needed to convert the raw acoustic data into said images. Utilizing this novel high-resolution ultrasound imaging sensor, we wish to investigate the limits of both passive and active airborne ultrasound sensing by utilizing this virtually artifact-free imaging modality.
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