3D Fabrication of 2D Mechanisms

International audienceThe success of physics sandbox applications and physics-based puzzle games is a strong indication that casualusers and hobbyists enjoy designing mechanisms, for educational or entertainment purposes. In these applications,a variety of mechanisms are designed by assembling two-dimensional shapes, creating gears, cranks, cams, andracks. The experience is made enjoyable by the fact that the user does not need to worry about the intricategeometric details that would be necessary to produce a real mechanism.In this paper, we propose to start from such casual designs of mechanisms and turn them into a 3D model that canbe printed onto widely available, inexpensive filament based 3D printers. Our intent is to empower the users ofsuch tools with the ability to physically realize their mechanisms and see them operate in the real world.To achieve this goal we tackle several challenges. The input 2D mechanism allows for some parts to overlap duringsimulation. These overlapping parts have to be resolved into non–intersecting 3D parts in the real mechanism.We introduce a novel scheme based on the idea of including moving parts into one another whenever possible.This reduces bending stresses on axles compared to previous methods. Our approach supports sliding parts andarbitrarily shaped mechanical parts in the 2D input. The exact 3D shape of the parts is inferred from the 2D inputand the simulation of the mechanism, using boolean operations between shapes. The input mechanism is oftensimply attached to the background. We automatically synthesize a chassis by formulating a topology optimizationproblem, taking into account the stresses exerted by the mechanism on the chassis through time

Multiple-Material Topology Optimization of Compliant Mechanisms Created via Polyjet 3D Printing

Compliant mechanisms are able to transfer motion, force, and energy using a monolithic structure without discrete hinge elements. The geometric design freedoms and multi-material capability offered by the PolyJet 3D printing process enables the fabrication of compliant mechanisms with optimized topology. The inclusion of multiple materials in the topology optimization process has the potential to eliminate the narrow, weak, hinge-like sections that are often present in single-material compliant mechanisms. In this paper, the authors propose a design and fabrication process for the realization of 3-phase, multiple-material compliant mechanisms. The process is tested on a 2D compliant force inverter. Experimental and theoretical performance of the resulting 3-phase inverter is compared against a standard 2-phase design.Mechanical Engineerin

Additively manufacturable micro-mechanical logic gates.

Early examples of computers were almost exclusively based on mechanical devices. Although electronic computers became dominant in the past 60 years, recent advancements in three-dimensional micro-additive manufacturing technology provide new fabrication techniques for complex microstructures which have rekindled research interest in mechanical computations. Here we propose a new digital mechanical computation approach based on additively-manufacturable micro-mechanical logic gates. The proposed mechanical logic gates (i.e., NOT, AND, OR, NAND, and NOR gates) utilize multi-stable micro-flexures that buckle to perform Boolean computations based purely on mechanical forces and displacements with no electronic components. A key benefit of the proposed approach is that such systems can be additively fabricated as embedded parts of microarchitected metamaterials that are capable of interacting mechanically with their surrounding environment while processing and storing digital data internally without requiring electric power

Determining the electronic performance limitations in top-down fabricated Si nanowires with mean widths down to 4 nm

Silicon nanowires have been patterned with mean widths down to 4 nm using top-down lithography and dry etching. Performance-limiting scattering processes have been measured directly which provide new insight into the electronic conduction mechanisms within the nanowires. Results demonstrate a transition from 3-dimensional (3D) to 2D and then 1D as the nanowire mean widths are reduced from 12 to 4 nm. The importance of high quality surface passivation is demonstrated by a lack of significant donor deactivation, resulting in neutral impurity scattering ultimately limiting the electronic performance. The results indicate the important parameters requiring optimization when fabricating nanowires with atomic dimensions

Microfabrication of Three-Dimensional Structures in Polymer and Glass by Femtosecond Pulses

We report three-dimensional laser microfabrication, which enables microstructuring of materials on the scale of 0.2-1 micrometers. The two different types of microfabrication demonstrated and discussed in this work are based on holographic recording, and light-induced damage in transparent dielectric materials. Both techniques use nonlinear optical excitation of materials by ultrashort laser pulses (duration < 1 ps).Comment: This is a proceedings paper of bi-lateral Conf. (Republics of China & Lithuania) on Optoelectronics and Magnetic Materials, Taipei, May 25-26, 2002.

Freeform Bioprinting of Liver Encapsulated in Alginate Hydrogels Tissue Constructs for Pharmacokinetic Study

An in vitro model that can be realistically and inexpensively used to predict human response to various drug administration and toxic chemical exposure is needed. By fabricating a microscale 3D physiological tissue construct consisting of an array of channels and tissue-embedded chambers, one can selectively develop various biomimicking mammalian tissues for a number of pharmaceutical applications, for example, experimental pharmaceutical screening for drug efficacy and toxicity along with apprehending the disposition and metabolic profile of a candidate drug. This paper addresses issues relating to the development and implementation of a bioprinting process for freeform fabrication of a 3D cell-encapsulated hydrogel-based tissue construct, the direct integration onto a microfluidic device for pharmacokinetic study, and the underlying engineering science for the fabrication of a 3D microscale tissue chamber as well as its application in pharmacokinetic study. To this end, a prototype 3D microfluidic tissue chamber embedded with liver cells encapsulated within a hydrogel matrix construct is bioprinted as a physiological in vitro model for pharmacokinetic study. The developed fabrication processes are further validated and parameters optimized by assessing cell viability and liver cell phenotype, in which metabolic and synthetic liver functions are quantitated.Mechanical Engineerin

Compliant rolling-contact architected materials for shape reconfigurability.

Architected materials can achieve impressive shape-changing capabilities according to how their microarchitecture is engineered. Here we introduce an approach for dramatically advancing such capabilities by utilizing wrapped flexure straps to guide the rolling motions of tightly packed micro-cams that constitute the material's microarchitecture. This approach enables high shape-morphing versatility and extreme ranges of deformation without accruing appreciable increases in strain energy or internal stress. Two-dimensional and three-dimensional macroscale prototypes are demonstrated, and the analytical theory necessary to design the proposed materials is provided and packaged as a software tool. An approach that combines two-photon stereolithography and scanning holographic optical tweezers is demonstrated to enable the fabrication of the proposed materials at their intended microscale

Nanoscale precision of 3D polymerisation via polarisation control

A systematic analysis of polarization effects in a direct write femtosecond laser 3D lithography is presented. It is newly shown that coupling between linear polarization of the writing light electric field and temperature gradient can be used to fine-tune feature sizes in structuring of photoresists at a nanoscale. The vectorial Debye focusing is used to simulate polarization effects and a controlled variation up to 20% in the linewidth is shown experimentally for the identical axial extent of the polymerised features. The revealed mechanisms are relevant for a wide range of phenomena of light-matter interaction at tight focusing in laser-tweezers and in plasmonic or dielectric sub-wavelength focusing where strong light intensity and thermal gradients coexist.Comment: 15 pages, 3 figure