Design and Fabrication of Soft 3D Printed Actuators: Expanding Soft Robotics Applications

Soft pneumatic actuators are ideal for soft robotic applications due to their innate compliance and high power-weight ratios. Presently, the majority of soft pneumatic actuators are used to create bending motions, with very few able to produce significant linear movements. Fewer can actively produce strains in multiple directions. The further development of these actuators is limited by their fabrication methods, specifically the lack of suitable stretchable materials for 3D printing. In this thesis, a new highly elastic resin for digital light projection 3D printers, designated ElastAMBER, is developed and evaluated, which shows improvements over previously synthesised elastic resins. It is prepared from a di-functional polyether urethane acrylate oligomer and a blend of two different diluent monomers. ElastAMBER exhibits a viscosity of 1000 mPa.s at 40 °C, allowing easy printing at near room temperatures. The 3D-printed components present an elastomeric behaviour with a maximum extension ratio of 4.02 ± 0.06, an ultimate tensile strength of (1.23 ± 0.09) MPa, low hysteresis, and negligible viscoelastic relaxation

Processes and materials used for direct writing technologies:A review

Direct Writing (DW), also known as Robocasting, is an extrusion-based layer-by-layer manufacturing technique suitable for manufacturing complex geometries. Different types of materials such as metals, composites, ceramics, biomaterials, and shape memory alloys can be used for DW. The simplicity and cost-efficiency of DW makes it convenient for different applications, from biomedical to optics. Recent studies on DW show a tendency towards the development of new materials and applications. This represents the necessity of a deep understanding of the principles and parameters of each technique, material, and process challenge. This review highlights the principles of many DW techniques, the recent advancements in material development, applications, process parameters, and challenges in each DW process. Since the quality of the printed parts by DW highly depend on the material extrusion, the focus of this review is mainly on the ceramic extrusion process and its challenges from rheological and material development point of view. This review delivers an insight into DW processes and the challenges to overcome for development of new materials and applications. The main objective of the review is to deliver necessary information for non-specialist and interdisciplinary researchers

Inkjet printing of functional materials for optical and photonic applications

Inkjet printing, traditionally used in graphics, has been widely investigated as a valuable tool in the preparation of functional surfaces and devices. This review focuses on the use of inkjet printing technology for the manufacturing of different optical elements and photonic devices. The presented overview mainly surveys work done in the fabrication of micro-optical components such as microlenses, waveguides and integrated lasers; the manufacturing of large area light emitting diodes displays, liquid crystal displays and solar cells; as well as the preparation of liquid crystal and colloidal crystal based photonic devices working as lasers or optical sensors. Special emphasis is placed on reviewing the materials employed as well as in the relevance of inkjet in the manufacturing of the different devices showing in each of the revised technologies, main achievements, applications and challenges

Processes and materials used for direct writing technologies: A review

Corrigendum to “Processes and materials used for direct writing technologies: A review” [Results in Engineering (2021) 11, 100257], 17 November 2021, 100308: ☆ The authors regret there is an update to Acknowledgments: This work was funded as part of the DiWoCiS project, which has received funding from the Katip Çelebi-Newton Fund Institutional Links Grants of The Scientific and Technological Research Council of Turkey and British Council. ☆☆ The authors would like to apologise for any inconvenience caused.Direct Writing (DW), also known as Robocasting, is an extrusion-based layer-by-layer manufacturing technique suitable for manufacturing complex geometries. Different types of materials such as metals, composites, ceramics, biomaterials, and shape memory alloys can be used for DW. The simplicity and cost-efficiency of DW makes it convenient for different applications, from biomedical to optics. Recent studies on DW show a tendency towards the development of new materials and applications. This represents the necessity of a deep understanding of the principles and parameters of each technique, material, and process challenge. This review highlights the principles of many DW techniques, the recent advancements in material development, applications, process parameters, and challenges in each DW process. Since the quality of the printed parts by DW highly depend on the material extrusion, the focus of this review is mainly on the ceramic extrusion process and its challenges from rheological and material development point of view. This review delivers an insight into DW processes and the challenges to overcome for development of new materials and applications. The main objective of the review is to deliver necessary information for non-specialist and interdisciplinary researchers.Newton Fund Institutional Links Grants - British Counci

Manipulation of polymeric fluids through pyro-electro-hydro-dynamics

This thesis is focused on the manipulation of liquids and polymeric fluids in a non-contact and electrode-free way, exploiting pyro-electro-hydro-dynamic systems. The thesis structure provides an introduction based on the theory and the combination between pyroelectric and electro-hydro-dynamic effect, with a focus on the developed techniques, followed by the presentation of the realized works. It will be presented the fabrication of micro-optical devices, in particular micro-lenses, through pyro-electro-hydro-dynamic effect. The attention will be directed toward the fabrication methods: in fact, they have been obtained by an ink-jet technology or through self-assembly on a micro-engineered pyroelectric crystal. In the first case, a new pyro-ink-jet set-up will be proposed and further modifications of the set-up, which will improve the flexibility of the technique, will be reported. The realized micro-lenses will be optically and geometrically characterized and it will be presented the fabrication of a multi-component device as an example of application of this technique. It will be shown that pyro-ink-jet printing permit to realize very uniform micro-lenses arrays with high resolution (diameter ̴ 300 nm). The second approach is based on the self-assembly of a micro-lenses array on a micro-engineered pyroelectric crystal. It will be showed an array decoration by nano-particles, such as quantum dots, and it will be presented the di-electro-phoretic effect on the employed dots. In particular, the study will focus on the effect of the patterned substrate on the localization of the nano-particles and on the investigation of the dots pattern transfer. Moreover, it will be shown another application of pyro-ink-jet printing: the capability of this system in the highly viscous solution manipulation allows the deposition of polymeric fibers and, in particular, how a fiber like these can be used as a component in a microfluidic channel. That demonstrates pyro-ink-jet printer is also an alternative to the classic electro-spinning system, avoiding electrodes and spiraling effect during the deposition. Produced fibers show great uniformity and reach thicknesses until the nano-metric scale. Moreover, there will be illustrated all the procedures realized to produce the micro-channel

Design, Development, and Testing of a Low Cost, Additively-Manufactured, Centrifugal Compressor

The three objectives of this research were to: 1.) design, build, and test AM compressors to substitute into COTS micro-gas turbine engines, 2.) provide initial correlations between FEA and compressor failure speed, and 3.) characterize the effects of AM on compressor performance. These goals improved the design cycle cost and the design-validation time cycle. ULTEM 9085, 300-AMB, and Onyx-Kevlar temperature-dependent tensile properties were measured. FEA-predicted failure speeds of stock compressor designs led design improvements, potentially fulfilling the original compressor requirements. Physical testing of the stock and ULTEM 9085 compressors occurred. Comparing these compressors\u27 performances demonstrated that low cost, AM materials are viable alternatives for certain micro-turbine applications. An improved Onyx-Carbon Fiber compressor was tested to failure. These results provide a proof of concept supporting AM compressors, improving the development time cycle. This approach enables high-risk yet low-cost research and development. Additionally, with proper mission planning, low-cost AM compressors could provide significant improvements to engine cost and weight for limited-life applications

Functional Materials and Techniques for Additive Manufacturing in Soft Robotics

This thesis outlines the development of new elastomeric materials and manufacturing processes for soft robotics. Specifically, this work describes the development of custom material formulations for use in additive manufacturing, additive manufacturing processing techniques for silicone elastomers, and multi-component additive manufacturing techniques. Material synthesis and processing is a gap in the field that needs more research to produce more predictable, higher quality, and more scalable soft robot technologies. This thesis includes papers that address the above topics, preceded by an introduction and literature review into additive manufacturing and materials characterization for soft robotics. The first work (Chapter 2) outlines the development of a custom elastomer designed to make biodegradable soft robots via 3D printing. The second work (Chapter 3) shows how liquid silicone thermoset polymers 3d printing can be improved by controlling reaction kinetics and rheology. The last work (Chapter 4) describes the process of using silicone 3D printing to embed multiple discrete sensing and electronic components into a functioning soft wearable device, with a focus on customizability. Each work describes a different part of how materials science plays a role in soft robotics, including the creation of elastomeric material, control of the elastomeric material, and combining the multiple materials in custom device manufacturing. For each work, a soft robot actuator or robot system is developed to emphasize the importance of material behavior and process development in improving soft robot manufacturing

A Digital Manufacturing Process For Three-Dimensional Electronics

Additive manufacturing (AM) offers the ability to produce devices with a degree of three-dimensional complexity and mass customisation previously unachievable with subtractive and formative approaches. These benefits have not transitioned into the production of commercial electronics that still rely on planar, template-driven manufacturing, which prevents them from being tailored to the end user or exploiting conformal circuitry for miniaturisation. Research into the AM fabrication of 3D electronics has been demonstrated; however, because of material restrictions, the durability and electrical conductivity of such devices was often limited. This thesis presents a novel manufacturing approach that hybridises the AM of polyetherimide (PEI) with chemical modification and selective light-based synthesis of silver nanoparticles to produce 3D electronic systems. The resulting nanoparticles act as a seed site for the electroless deposition of copper. The use of high-performance materials for both the conductive and dielectric elements created devices with the performance required for real-world applications. For printing PEI, a low-cost fused filament fabrication (FFF); also known as fused deposition modelling (FDM), printer with a unique inverted design was developed. The orientation of the printer traps hot air within a heated build environment that is open on its underside allowing the print head to deposit the polymer while keeping the sensitive components outside. The maximum achievable temperature was 120 °C and was found to reduce the degree of warping and the ultimate tensile strength of printed parts. The dimensional accuracy was, on average, within 0.05 mm of a benchmark printer and fine control over the layer thickness led to the discovery of flexible substrates that can be directly integrated into rigid parts. Chemical modification of the printed PEI was used to embed ionic silver into the polymer chain, sensitising it to patterning with a 405 nm laser. The rig used for patterning was a re-purposed vat-photopolymerisation printer that uses a galvanometer to guide the beam that is focused to a spot size of 155 µm at the focal plane. The positioning of the laser spot was controlled with an open-sourced version of the printers slicing software. The optimal laser patterning parameters were experimentally validated and a link between area-related energy density and the quality of the copper deposition was found. In tests where samples were exposed to more than 2.55 J/cm^2, degradation of the polymer was experienced which produced blistering and delamination of the copper. Less than 2.34 J/cm^2 also had negative effect and resulted in incomplete coverage of the patterned area. The minimum feature resolution produced by the patterning setup was 301 µm; however, tests with a photomask demonstrated features an order of magnitude smaller. The non-contact approach was also used to produce conformal patterns over sloped and curved surfaces. Characterisation of the copper deposits found an average thickness of 559 nm and a conductivity of 3.81 × 107 S/m. Tape peel and bend fatigue testing showed that the copper was ductile and adhered well to the PEI, with flexible electronic samples demonstrating over 50,000 cycles at a minimum bend radius of 6.59 mm without failure. Additionally, the PEI and copper combination was shown to survive a solder reflow with peak temperatures of 249°C. Using a robotic pick and place system a test board was automatically populated with surface mount components as small as 0201 resistors which were affixed using high-temperature, Type-V Tin-Silver-Copper solder paste. Finally, to prove the process a range of functional demonstrators were built and evaluated. These included a functional timer circuit, inductive wireless power coils compatible with two existing standards, a cylindrical RF antenna capable of operating at several frequencies below 10 GHz, flexible positional sensors, and multi-mode shape memory alloy actuators

3D Printed Microfluidic Devices

3D printing has revolutionized the microfabrication prototyping workflow over the past few years. With the recent improvements in 3D printing technologies, highly complex microfluidic devices can be fabricated via single-step, rapid, and cost-effective protocols as a promising alternative to the time consuming, costly and sophisticated traditional cleanroom fabrication. Microfluidic devices have enabled a wide range of biochemical and clinical applications, such as cancer screening, micro-physiological system engineering, high-throughput drug testing, and point-of-care diagnostics. Using 3D printing fabrication technologies, alteration of the design features is significantly easier than traditional fabrication, enabling agile iterative design and facilitating rapid prototyping. This can make microfluidic technology more accessible to researchers in various fields and accelerates innovation in the field of microfluidics. Accordingly, this Special Issue seeks to showcase research papers, short communications, and review articles that focus on novel methodological developments in 3D printing and its use for various biochemical and biomedical applications