Prototyping Large-Sized Objects Using Freeform Thick Layers of Plastic Foam

Current Rapid Prototyping systems are primarily aimed at small-sized objects containing many shape details. In this paper a Rapid Prototyping technology is presented that is aimed at largesized objects having a complex, freeform outer shape. This new technology builds the model out ofthick layers, each having freeform outside faces. The paper will present: an overview of current methods to produce large prototypes, the basics of the new method, the technology used to produce the layers, the toolpath planning and finally the overall system design.Mechanical Engineerin

A Review of State-of-the-Art Large Sized Foam Cutting Rapid Prototyping and Manufacturing Technologies.

Purpose – Current additive rapid prototyping (RP) technologies fail to efficiently produce objects greater than 0.5?m3 due to restrictions in build size, build time and cost. A need exists to develop RP and manufacturing technologies capable of producing large objects in a rapid manner directly from computer-aided design data. Foam cutting RP is a relatively new technology capable of producing large complex objects using inexpensive materials. The purpose of this paper is to describe nine such technologies that have been developed or are currently being developed at institutions around the world. The relative merits of each system are discussed. Recommendations are given with the aim of enhancing the performance of existing and future foam cutting RP systems. Design/methodology/approach – The review is based on an extensive literature review covering academic publications, company documents and web site information. Findings – The paper provides insights into the different machine configurations and cutting strategies. The most successful machines and cutting strategies are identified. Research limitations/implications – Most of the foam cutting RP systems described have not been developed to the commercial level, thus a benchmark study directly comparing the nine systems was not possible. Originality/value – This paper provides the first overview of foam cutting RP technology, a field which is over a decade old. The information contained in this paper will help improve future developments in foam cutting RP systems

Active Device Fabrication Using Fiber Encapsulation Additive Manufacturing

Fiber Encapsulation Additive Manufacturing (FEAM) is a novel solid freeform fabrication process in which a fiber and a matrix are co-deposited simultaneously within a single printer along straight and curved 2-D and 3-D paths. Using a FEAM approach in which the fiber is a metal wire and the matrix is a thermoplastic polymer, simple electromechanical devices such as voice coils, inductive sensors, and membrane switches have been successfully produced. This paper will present an overview of the FEAM process, describe several fabricated devices, and discuss recent developments in controllably stopping and starting the wire, and in creating electrical junctions between individual wires, which together enable much more complex devices to be made.Mechanical Engineerin

Langley aerospace test highlights, 1985

The role of the Langley Research Center is to perform basic and applied research necessary for the advancement of aeronautics and space flight, to generate new and advanced concepts for the accomplishment of related national goals, and to provide research advice, technological support, and assistance to other NASA installations, other government agencies, and industry. Significant tests which were performed during calendar year 1985 in Langley test facilities, are highlighted. Both the broad range of the research and technology activities at the Langley Research Center and the contributions of this work toward maintaining United States leadership in aeronautics and space research, are illustrated. Other highlights of Langley research and technology for 1985 are described in Research and Technology-1985 Annual Report of the Langley Research Center

Feature-based process planning for CNC machining

Journal ArticleToday CNC machining is used successfully to provide program-driven medium lot size manufacturing. The range of applicability of CNC machining should be greater: For small lot sizes such as prototyping or custom products, these machines should provide quick turnaround and flexible production scheduling. To set up for larger lot size production, the CNC machines can be used to construct small lots of production tooling, such as jigs, fixtures, molds and dies

Mechanics and applications of stretchable serpentine structures

Stretchable structures have been developed for various applications, including expandable coronary stents, deployable sensor networks and stretchable bio-mimetic and bio-integrated electronics. High-performance, stretchable electronics have to utilize high-quality and long-lasting inorganic electronic materials such as silicon, oxide dielectrics and metals, which are intrinsically stiff and often brittle. It is therefore an interdisciplinary challenge to make inorganic electronics stretchable while retaining their electronic functionality. Patterning stiff materials into serpentine-shaped wavy ribbons has become a popular strategy for fabricating stretchable inorganic electronics. However due to a lack of mechanics understanding, design of serpentine structures is still largely empirical, whether for freestanding or substrate supported serpentines. This dissertation systematically investigates the mechanics of serpentine structures with emphasis on the effects of serpentine geometry and substrate stiffness, which involves theoretical analysis, numerical simulation, and experimental validation. Our theory has successfully predicted the stretchability and stiffness of various serpentine shapes and has been applied to the optimization of serpentine designs under practical constraints. We are also the first to point out that not all geometric effects are monotonic and serpentines are not always more stretchable than linear ribbons. To manufacture high quality serpentine ribbons with high throughput and low cost, we have invented a “cut-and-paste” method to fabricate both metallic and ceramic serpentines. As a demonstration of our method, a noninvasive, tattoo-like multifunctional epidermal sensor system has been built for the measurement of electrophysiological signals, skin temperature, skin hydration, and respiratory rate. Engineering of epidermal stretchable antenna for wireless communication is also detailed and rationalized.Mechanical Engineerin

The Application of Advanced Product Development Techniques to a 1st Year Engineering Student Boat Design Project

The design and manufacture of a RC model boat is a component of the compulsory paper ENGG180 for first year engineering students at the University of Waikato. ENGG180 is a foundation of engineering paper which includes project-based learning, fundamental principles of engineering design and engineering analysis. The model boats made by undergraduate engineering students are rather primitive in design and use conventional manufacturing methods. The conventional methods used by students, to make the hulls are a very labour intense and inaccurate. In the present method there is no direct link between the CAD model and the manufactured hull due to the absence of computer-aided machining. However using conventional methods, students get more knowledge on how parts are manufactured. These conventional methods of fabrication are used because the primary emphasis for their project is experiencing the design process, working effectively in a team and working to constraints (such as time, money and materials). The current emphasis is not fabrication technologies. Students would gain more accurate impressions of design and fabrication if more up-to-date technologies were demonstrated. The purpose of this research is to teach students about the designs and features of a fast boat, modern manufacturing methodologies and rapid prototyping. The boat was designed in Solidworks, the hull mold was machined using a CNC milling machine directly from the CAD model. The many internal pats were produced with laser cutting machine from the CAD model. Thus the model boat was built accurately to the CAD model. These methods demonstrated have modern CAD and CAM techniques which could be successfully applied to the manufacture of model boat. It was found that the boat did not perform as expected this was due to problem with battery performance. It is therefore suggested that if further work be undertaken in this area more detailed modelling and simulation (CAE) of the boat system be carried out

Automatic Romaine Heart Harvester

The Romaine Robotics Senior Design Team developed a romaine lettuce heart trimming system in partnership with a Salinas farm to address a growing labor shortage in the agricultural industry that is resulting in crops rotting in the field before they could be harvested. An automated trimmer can alleviate the most time consuming step in the cut-trim-bag harvesting process, increasing the yields of robotic cutters or the speed of existing laborer teams. Leveraging the Partner Farm’s existing trimmer architecture, which consists of a laborer loading lettuce into sprungloaded grippers that are rotated through vision and cutting systems by an indexer, the team redesigned geometry to improve the loading, gripping, and ejection stages of the system. Physical testing, hand calculations, and FEA were performed to understand acceptable grip strengths and cup design, and several wooden mockups were built to explore a new actuating linkage design for the indexer. The team manufactured, assembled, and performed verification testing on a full-size metal motorized prototype that can be incorporated with the Partner Farm’s existing cutting and vision systems. The prototype met all of the established requirements, and the farm has implemented the redesign onto their trimmer. Future work would include designing and implementing vision and cutting systems for the team’s metal prototype