Doctor of Philosophy

dissertationTactile sensors are a group of sensors that are widely being developed for transduction of touch, force and pressure in the field of robotics, contact sensing and gait analysis. These sensors are employed to measure and register interactions between contact surfaces and the surrounding environment. Since these sensors have gained usage in the field of robotics and gait analysis, there is a need for these sensors to be ultra flexible, highly reliable and capable of measuring pressure and two-axial shear simultaneously. The sensors that are currently available are not capable of achieving all the aforementioned qualities. The goal of this work is to design and develop such a flexible tactile sensor array based on a capacitive sensing scheme and we call it the flexible tactile imager (FTI). The developed design can be easily multiplexed into a high-density array of 676 multi-fingered capacitors that are capable of measuring pressure and two-axial shear simultaneously while maintaining sensor flexibility and reliability. The sensitivity of normal and shear stress for the FTI are 0.74/MPa and 79.5/GPa, respectively, and the resolvable displacement and velocity are as low as 60 µm and 100 µm/s, respectively. The developed FTI demonstrates the ability to detect pressure and shear contours of objects rolling on top of it and capability to measure microdisplacement and microvelocities that are desirable during gait analysis

Roadmap on semiconductor-cell biointerfaces.

This roadmap outlines the role semiconductor-based materials play in understanding the complex biophysical dynamics at multiple length scales, as well as the design and implementation of next-generation electronic, optoelectronic, and mechanical devices for biointerfaces. The roadmap emphasizes the advantages of semiconductor building blocks in interfacing, monitoring, and manipulating the activity of biological components, and discusses the possibility of using active semiconductor-cell interfaces for discovering new signaling processes in the biological world

High-resolution 3D direct-write prototyping for healthcare applications

The healthcare sector has much to benefit from the vast array of novelties erupting from the manufacturing world. 3D printing (additive manufacturing) is amongst the most promising recent inventions with much research concentrated around the various approaches of 3D printing and applying this effectively in the health sector. Amongst these methods, the direct-write assembly approach is a promising candidate for rapid prototyping and manufacturing of miniaturised medical devices/sensors and in particular, miniaturised flexible capacitive pressure sensors. Microstructuring the dielectric medium of capacitive pressure sensors enhances the sensitivity of the capacitive pressure sensor. The structuring has been predominantly achieved with photolithography and similar subtractive approaches. In this project high-resolution 3D direct write printing was used to fabricate structured dielectric mediums for capacitive pressure sensors. This involved the development and rheological characterisation of printability-tuned water soluble polyvinyl pyrrolidone (PVP) based inks (10%-30% polymer content) for stable high-resolution 3D printing. These inks were used to print water soluble micromoulds that were filled and cured with otherwise difficult to structure low G’ materials like PDMS. Our approach essentially decouples ink synthesis from printability at the micrometre scale. The developed micro moulding approach was employed for printing pyramidal micro moulds, that were used as templates for fabricating pyramid structured dielectric mediums for capacitive pressure sensing. The power of the approach was used to alter the microstructures and reap enhanced pressure sensing characteristics for effective miniaturised capacitive pressure sensors. A pressure sensing ring – that could be worn by doctors and surgeons – was prototyped with our approach and employed successfully to monitor in real-time the radial pulse signal of a 29 year old male volunteer. The print resolution of the inks was enhanced by formulating and rheologically characterising a PVP/PVDF polymer blend ink that would wet the printing nozzle less due to the hydrophobicity of the PVDF

Finite element modeling and validation of a soft array of spatially coupled dielectric elastomer transducers

Dielectric elastomer (DE) transducers are suitable candidates for the development of compliant mechatronic devices, such as wearable smart skins and soft robots. If many independently-controllable DEs are closely arranged in an array-like configuration, sharing a common elastomer membrane, novel types of cooperative and soft actuator/sensor systems can be obtained. The common elastic substrate, however, introduces strong electro-mechanical coupling effects among neighboring DEs, which highly influence the overall membrane system actuation and sensing characteristics. To effectively design soft cooperative systems based on DEs, these effects need to be systematically understood and modeled first. As a first step towards the development of soft cooperative DE systems, in this paper we present a finite element simulation approach for a 1-by-3 silicone array of DE units. After defining the system constitutive equations and the numerical assumptions, an extensive experimental campaign is conducted to calibrate and validate the model. The simulation results accurately predict the changes in force (actuation behavior) and capacitance (sensing behavior) of the different elements of the array, when their neighbors are subjected to different electro-mechanical loads. Quantitatively, the model reproduces the force and capacitance responses with an average fit higher than 93% and 92%, respectively. Finally, the validated model is used to perform parameter studies, aimed at highlighting how the array performance depends on a relevant set of design parameters, i.e. DE-DE spacing, DE-outer structure spacing, membrane pre-stretch, array scale, and electrode shape. The obtained results will provide important guidelines for the future design of cooperative actuator/sensor systems based on DE transducers

Soft Tactile Sensors for Mechanical Imaging

Tactile sensing aims to electronically capture physical attributes of an object via mechanical contact. It proves indispensable to many engineering tasks and systems, in areas ranging from manufacturing to medicine and autonomous robotics. Biological skin, which is highly compliant, is able to perform sensing under challenging and highly variable conditions with levels of performance that far exceed what is possible with conventional tactile sensors, which are normally fabricated with non-conforming materials. The development of stretchable, skin-like tactile sensors has, as a result, remained a longstanding goal of engineering. However, to date, artificial tactile sensors that might mimic both the mechanical and multimodal tactile sensory capabilities of biological skin remain far from realization, due to the challenges of fabricating spatially dense, mechanically robust, and compliant sensors in elastic media. Inspired by these demands, this dissertation addresses many aspects of the challenging problem of engineering skin-like electronic sensors. In the first part of the thesis, new methods for the design and fabrication of thin, highly deformable, high resolution tactile sensors are presented. The approach is based on a novel configuration of arrays of microfluidic channels embedded in thin elastomer membranes. To form electrodes, these channels are filled with a metal alloy, eutectic Gallium Indium, that remains liquid at room temperature. Using capacitance sensing techniques, this approach achieves sensing resolutions of 1 mm$^{-1}$. To fabricate these devices, an efficient and robust soft lithography method is introduced, based on a single step cast. An analytical model for the performance of these devices is derived from electrostatic theory and continuum mechanics, and is demonstrated to yield excellent agreement with measured performance. This part of the investigation identified fundamental limitations, in the form of nonmonotonic behavior at low strains, that is demonstrated to generically affect solid cast soft capacitive sensors. The next part of the thesis is an investigation of new methods for designing soft tactile sensors based on multi-layer heterogeneous 3D structures that combine active layers, containing embedded liquid metal electrodes, with passive and mechanically tunable layers, containing air cavities and micropillar geometric supports. In tandem with analytical and computational modeling, these methods are demonstrated to facilitate greater control over mechanical and electronic performance. A new soft lithography fabrication method is also presented, based on the casting, alignment, and fusion of multiple functional layers in a soft polymer substrate. Measurements indicate that the resulting devices achieve excellent performance specifications, and avoid the limiting nonmonotonic behavior identified in the first part of the thesis. In order to demonstrate the practical utility of the devices, we used them to perform dynamic two-dimensional tactile imaging under distributed indentation loads. The results reflect the excellent static and dynamic performance of these devices. The final part of the thesis investigates the utility of the tactile sensing methods pursued here for imaging lumps embedded in simulated tissue. In order to facilitate real-time sensing, an electronic system for fast, array based measurement of small, sub-picofarad (pF) capacitance levels was developed. Using this system, we demonstrated that it is possible to accurately capture strain images depicting small lumps embedded in simulated tissue with either an electronic imaging system or a sensor worn on the finger, supporting the viability of wearable sensors for tactile imaging in medicine. In conclusion, this dissertation confronts many of the most vexing problems arising in the pursuit of skin-like electronic sensors, including fundamental operating principles, structural and functional electronic design, mechanical and electronic modeling, fabrication, and applications to biomedical imaging. The thesis also contributes knowledge needed to enable applications of tactile sensing in medicine, an area that has served as a key source of motivation for this work, and aims to facilitate other applications in areas such as manufacturing, robotics, and consumer electronics.Ph.D., Electrical Engineering -- Drexel University, 201