2,749 research outputs found
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Transferring Unit Cell Based Tissue Scaffold Design to Solid Freeform Fabrication
Designing for the freeform fabrication of heterogeneous tissue scaffold is always a challenge in
Computer Aided Tissue Engineering. The difficulties stem from two major sources: 1)
limitations in current CAD systems to assembly unit cells as building blocks to form complex
tissue scaffolds, and 2) the inability to generate tool paths for freeform fabrication of unit cell
assemblies. To overcome these difficulties, we have developed an abstract model based on
skeletal representation and associated computational methods to assemble unit cells into an
optimized structure. Additionally we have developed a process planning technique based on
internal architecture pattern of unit cells to generate tool paths for freeform fabrication of tissue
scaffold. By modifying our optimization process, we are able to transfer an optimized design to
our fabrication system via our process planning technique.Mechanical Engineerin
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Biomimetic Design and Fabrication of Interior Architecture of Tissue Scaffolds Using Solid Freeform Fabrication
Modeling, design and fabrication of tissue scaffolds with intricate architecture,
porosity and pore size for desired tissue properties presents a challenge in tissue engineering.
This paper will present the details of our development in designing and fabrication of the
interior architecture of scaffolds using a novel design approach. The Interior Architecture
Design (IAD) approach seeks to generate scaffold layered freeform fabrication tool path without
forming complicated 3D CAD scaffold models. This involves: applying the principle of layered
manufacturing to determine the scaffold individual layered process planes and layered contour;
defining the 2D characteristic patterns of the scaffold building blocks (unit cells) to form the
Interior Scaffold Pattern; and the generation of process tool path for freeform fabrication of
these scaffolds with the specified interior architecture. Feasibility studies applying the IAD
algorithm to example models and the generation of fabrication planning instructions will be
presented.Mechanical Engineerin
Research Towards High Speed Freeforming
Additive manufacturing (AM) methods are currently utilised for the manufacture of prototypes and low volume, high cost parts. This is because in most cases the high material costs and low volumetric deposition rates of AM parts result in higher per part cost than traditional manufacturing methods. This paper brings together recent research aimed at improving the economics of AM, in particular Extrusion Freeforming (EF).
A new class of machine is described called High Speed Additive Manufacturing (HSAM) in which software, hardware and materials advances are aggregated. HSAM could be cost competitive with injection moulding for medium sized medium quantity parts. A general outline for a HSAM machine and supply chain is provided along with future required research
Product Focused Freeform Fabrication Education
Presented in this paper is our experience of teaching freeform fabrication to students at
the Missouri University of Science and Technology, and to high school students and
teachers. The emphasis of the curriculum is exposing students to rapid product
development technologies with the goal of creating awareness to emerging career
opportunities in CAD/CAM. Starting from solid modeling, principles of freeform
fabrication, to applications of rapid prototyping and manufacturing in industry sponsored
product development projects, students can learn in-depth freeform fabrication
technologies. Interactive course content with hands-on experience for product
development is the key towards the success of the program.Mechanical Engineerin
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The Potential of Freeform Construction Processes
The level of automation technology and processes control found in modern day construction
lags significantly behind other industries such as automotive and aerospace. The construction
industry has health and safety issues and still uses traditional methods of procurement. These
problems are compounded by diminishing skills in the labour force. Methods of production
must change if these issues are to be resolved and Freeform Construction is a collection of
processes that could have potential impact. This paper outlines some of the major issues
facing construction and sets a context with examples of digital fabrication in construction.
Freeform Construction is defined and potential applications are presented and related to
application scale. The viability of two potential applications are investigated in terms of cost.Mechanical Engineerin
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Powder Deposition and Sintering for a Two-Powder Approach to Solid Freeform Fabrication
A two-powder approach is presented where Fused Deposition modeling (FDM) is used to
create a thin shell in the shape of the part to be fabricated. The shell is filled with powder of the
part material and surrounded by a support powder that has a high sintering temperature. Upon
compressing and sintering the shelVpowder system in a uniaxial hot press, the polymer shell burns
out and the support powder compresses the part powder. The part powder consolidates into the
desired part while the support material remains in powder form and can be easily removed. This
paper presents results ofinitial experimental studies.Mechanical Engineerin
Freeform Fabrication of Ionomeric Polymer-Metal Composite Actuators
Ionomeric polymer-metal composite (IPMC) actuators are a type of soft electromechanically active material which offers
large displacement, rapid motion with only ~1V stimulus. IPMC’s are entering commercial applications in toys (Ashley
2003) and biomedical devices (Soltanpour 2001; Shahinpoor 2002; Shahinpoor, Shahinpoor et al. 2003; Soltanpour and
Shahinpoor 2003; Soltanpour and Shahinpoor 2004), but unfortunately they can only actuate by bending, limiting their
utility. Freeform fabrication offers a possible means of producing IPMC with novel geometry and/or tightly integrated with
mechanisms which can yield linear or more complex motion. We have developed materials and processes which allow us to
freeform fabricate complete IPMC actuators and their fabrication substrate which will allow integration within other
freeform fabricated devices. We have produced simple IPMC’s using our multiple material freeform fabrication system, and
have demonstrated operation in air for more than 40 minutes and 256 bidirectional actuation cycles. The output stress scaled
to input power is two orders of magnitude inferior to that of the best reported performance for devices produced in the
traditional manner, but only slightly inferior to devices produced in a more similar manner. Possible explanations and paths
to improvement are presented. Freeform fabrication of complete electroactive polymer actuators in unusual geometries,
with tailored actuation behavior, and integrated with other freeform fabricated active components, will enable advances in
biomedical device engineering, biologically inspired robotics, and other fields. This work constitutes the first
demonstration of complete, functional, IPMC actuators produced entirely by freeform fabrication.Mechanical Engineerin
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Printing Embedded Circuits
Automated manufacturing technologies such as freeform fabrication can greatly
reduce the cost and complexity of infrastructure required to manufacture unique devices
or invent new technologies. Multi-material freeform fabrication processes under
development have the potential to automatically build complete functional devices
including electronics. Making this technology available to creative individuals will
revolutionize art and invention, but requires extensive simplification and cost reduction
of what is still a laboratory technology. The combination of a Fab@Home Model 1
personal fabrication system and commercially available materials allows the
demonstration of simple and inexpensive freeform fabrication of functional embedded
electrical circuits, and useful devices. Using this approach, we have been able to
demonstrate an LED flashlight, functional printed circuit boards in 2-dimensions and 3-
dimensions that are actually entirely printed, and a child’s toy with embedded circuitry.
These results, and the materials and methods involved in producing them will be
presented in detail.Mechanical Engineerin
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Rapid Fabrication of Large-sized Solid Shape using Variable Lamination Manufacturing and Multi-functional Hotwire Cutting System
Rapid prototyping (RP) technologies have been widely used to reduce the lead-time and
development cost of new products. The VLM-ST process has been developed to overcome the
currently developed RP technologies such as a large building time, a high building cost, an
additional post-processing and a large apparatus cost. However, the VLM-ST process has the
limitation of fabricated model size (VLM300: 297Ă—210 mm, VLM400: 420Ă—297 mm) and the
limitation of slope angle when the large-sized model more than 600 Ă— 600 Ă— 600 mm or
axisymmetric shape is fabricated. The objective of this paper is to develop a multi-functional
hotwire cutting system (MHC) using EPS-foam block or sheet as the working material in order to
fabricate a large-sized shape more than 600 Ă— 600 Ă— 600 mm. Because the MHC apparatus
employs a four-axis synchronized hotwire cutter with the structure of two XY movable heads and
a turn-table, it allows the easy fabrication of various 3D shapes, such as (1) an axisymmetric
shape or a sweeping cross-sectioned pillar shape using the hot-strip in the form of sweeping
surface and EPS foam block on the turn-table, (2) a polyhedral complex shape using the hotwire
and EPS foam block on the turn-table, and (3) a ruled surface approximated freeform shape using
the hotwire and EPS foam sheet. In order to examine the applicability of the developed MHC
apparatus, an axisymmetric shape, a polyhedral shape and a large-sized freeform shape were
fabricated by the apparatus.Mechanical Engineerin
The development of a finite elements based springback compensation tool for sheet metal products
Springback is a major problem in the deep drawing process. When the tools are released after the forming stage, the product springs back due to the action of internal stresses. In many cases the shape deviation is too large and springback compensation is needed: the tools of the deep drawing process are changed so, that the product becomes geometrically accurate after springback. In this paper, two different ways of geometric optimization are presented, the smooth displacement adjustment (SDA) method and the surface controlled overbending (SCO) method. Both methods use results from a finite elements deep drawing simulation for the optimization of the tool shape. The methods are demonstrated on an industrial product. The results are satisfactory, but it is shown that both methods still need to be improved and that the FE simulation needs to become more reliable to allow industrial application
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