Manufacturing Metallic Parts with Designed Mesostructure via Three-Dimensional Printing of Metal Oxide Powder

Cellular materials, metallic bodies with gaseous voids, are a promising class of materials that offer high strength accompanied by a relatively low mass. In this paper, the authors investigate the use of ThreeDimensional Printing (3DP) to manufacture metallic cellular materials by selectively printing binder into a bed of metal oxide ceramic powder. The resulting green part undergoes a thermal chemical post-process in order to convert it to metal. As a result of their investigation, the authors are able to create cellular materials made of maraging steel that feature wall sizes as small as 400 µm and angled trusses and channels that are 1 mm in diameter.Mechanical Engineerin

\u3cem\u3eGRASP News\u3c/em\u3e, Volume 6, Number 1

A report of the General Robotics and Active Sensory Perception (GRASP) Laboratory, edited by Gregory Long and Alok Gupta

Polymer Pen Printing: A Tool for Studying 2D Enzymatic Lithography and Printing 3D Carbon Features

Polymer Pen Lithography (PPL) is a promising molecular printing approach which combines the advantages of both microcontact printing (low cost, high-throughput) and the dip pen lithography (DPN) (arbitrary writing, high-resolution) into one cohesive lithography method to create 2 dimensional (2-D) patterns with micro/nano-features on different substrates. The goal of this dissertation is to design and develop a new tool based upon PPL, which is not limited to forming 2D parallel patterns, but can also create 3D complex microstructures, finding applications in both biotechnology and Micro-Electro-Mechanical systems (MEMS) technology. This novel approach is named Polymer Pen Printing. Different from PPL using traditional dry-ink printing methods, an inking step is added to each printing repetition in the polymer pen printing process. Thus a wide range of ink materials with diverse viscosities can be transferred to substrates to create functional 2D and 3D microstructures. The polymer pen printing apparatus used in this thesis has been accomplished and introduced in Chapter 2. As a preliminary attempt, the single polymer pen printing approach was developed by simply attaching a solid polydimethylsiloxane (PDMS) pen tip to a multi-axis robot for small microarray fabrication. Compared to the single pen printing method, multi-pen printing can create large arrays of features. Therefore, an improved apparatus for polymer pen printing with high-throughput was discussed and built. Silicon molds, which consist of hundreds of uniform pyramidal openings, were photolithographically defined and etched using hydrofluoric acid (HF) followed by potassium hydroxide solution; after surface-modification with fluorosilane, these silicon molds were used to cast arrays of PDMS pyramidal pen tip. The cast PDMS pen array was mounted to a hollow holder with a 45° mirror inside. Therefore, each PDMS pen can be observed and monitored from the microscope on the side. To achieve prints less than 1 micron across, a Z axis stage with nanometer resolution was incorporated; and to control the compression of PDMS pen tips, a force gauge was also incorporated to detect 1 mg of applied force from the tips. The printing process for the multi-pen system is almost the same as single pen system. PDMS pens are coated with ink solution before each printing cycle by dipping into an inkwell and then brought into contact with the substrate surface. Thus multiple patterns, one from each tip, are created in parallel simultaneously. Furthermore, with control of the printing force, feature sizes could be controlled over the range submicron to tens of microns. Three ink candidates have been printed by polymer pen printing approach to fabricate 2D&3D microstructures. The first ink material is Barium Strontium Titanate (BST) nanocrystallites dispersed in a furfuryl alcohol (FA), which was printed by the single PDMS pen with 100 μm tip diameter (Chapter 3). After printing, samples were heated to crosslink FA monomers, forming a stable polymeric matrix with embedded BST nanocrystallites. Without shear-thinning properties, BST/FA ink cannot be used to build 3D posts, but it has the capability to create circular patterns with different thickness by the single or multi-tier deposition method. It was found that the thickness of film increased linearly with the number of deposits without changing the diameter significantly. This encouraging result could enable the formation of microcapacitors with multi-tiered structure. Moreover, the study of printing parameters, including printing height and ink pick-up position, shows that changes to the pen positions in the ink reservoir or substrate have essentially no impact on deposit thickness or diameter. Beyond that, the effect of surface chemistry of PDMS pen and silicon wafer have also been studied. The plasma treated hydrophilic PDMS pen can pen transfer more BST/FA than untreated one; and the larger diameters with smaller thickness were obtained on a hydrophilic silicon wafer. The second ink candidate is a dilute aqueous solution of enzyme Candia antartica lipase B (CALB), which is known to catalyze the decomposition of poly (ε-caprolactone) (PCL) films. By bringing enzymes into contact with pre-defined regions of a surface, a polymer film can be selectively degraded to form patterned features that are requited for applications in biotechnology and electronics. This so-called enzymatic lithography is an environmentally friendly process as it does not require any actinic radiation or synthetic chemicals to develop required features. But the need to restrict the mobility of the enzyme in order to maintain control of feature sizes poses a significant challenge. In Chapter 4, after writing 2D enzyme patterns onto a spin-cast PCL film by single pen printing, samples with CALB were incubated at 37 ℃ and 95% relative humidity (RH) for up to 7 days to develop features. The CALB selectively degraded the PCL film during incubation, forming openings through the film. The size of these features (10 to 50 μm diameter) is well suited for use as biocompatible micro-reactors. Previous study of patterning CALB by single polymer pen printing technique resulted in slow etch rates, low throughput and poor image quality. In Chapter 5, I present an improved enzymatic lithography approach, still based on enzyme CALB and PCL system, which can resolve fine-scale features (\u3c 1 μm across) in thick (0.1 - 2.0 μm) polymer films after 5 minutes to 2 hours of incubation at 37 ℃ and 87% RH. Immobilization of the enzyme on the polymer surface was monitored using fluorescence microscopy by labeling CALB with FITC. The crystallite size in the PCL films was systematically varied; small crystallites resulted in significantly faster etch rates (20 nm/min) and the ability to resolve smaller features (as fine as 1 μm). The effect of printing conditions and RH during incubation is also presented. Patterns formed in the PCL film were transferred to an underlying copper foil demonstrating a Green approach to the fabrication of printed circuit boards. In parallel, the third ink material is a mixture of 25 wt% graphite dispersed in a high viscosity phenolic resin n-methyl-2-pyrrolidone (NMP) solution, which can be converted into carbon/carbon composites after a pyrolysis process. The 3D polymeric posts were created by depositing multilayers of thixotropic phenolic ink on a silicon substrate by single polymer pen printing method with a 10 μm radius PDMS pen tip (Chapter 6). After pyrolysis at 1000 ℃ in a nitrogen (N2) atmosphere, the polymeric features were converted to the glassy carbon/graphite features with a high aspect ratio (\u3e2). These features may be used as microelectrodes. Last, arrays of needle-shaped glassy carbon have been developed by a drawing approach using multi-pen printing technique followed by simple pyrolysis process (Chapter 7). To build polymeric needles with ultra-high aspect ratio, the polymeric ink was prepared by dissolving phenolic resin in the high boiling point (204 ℃) solvent NMP without fillers to achieve good printability and suitable viscosity. By slowly lifting up the print head from substrate, liquid needle structures were formed and then solidified on silicon substrates or gold electrodes due to the solvent evaporation. In addition, suspended resin fibers connected to two electrodes have also been fabricated by precisely controlling the movement of the PDMS pen. After pyrolysis, these resin features were converted to glassy carbon and the 3D structures remained. The electrical characterization results showed that glassy carbon made by this method had relatively low resistivity (2.5 x 10-5 Ωm). Therefore the glassy carbon based microneedles are well-suited to be electrodes for electrochemical sensors for biological applications

Understanding and Design of an Arduino-based PID Controller

This thesis presents research and design of a Proportional, Integral, and Derivative (PID) controller that uses a microcontroller (Arduino) platform. The research part discusses the structure of a PID algorithm with some motivating work already performed with the Arduino-based PID controller from various fields. An inexpensive Arduino-based PID controller designed in the laboratory to control the temperature, consists of hardware parts: Arduino UNO, thermoelectric cooler, and electronic components while the software portion includes C/C++ programming. The PID parameters for a particular controller are found manually. The role of different PID parameters is discussed with the subsequent comparison between different modes of PID controllers. The designed system can effectively measure the temperature with an error of ± 0.6℃ while a stable temperature control with only slight deviation from the desired value (setpoint) is achieved. The designed system and concepts learned from the control system serve in pursuing inexpensive and precise ways to control physical parameters within a desired range in our laboratory

Combinatorial ink-jet printing for ceramic discovery

PhDAn aspirating and dispensing printer established inside a robot gantry equipped with furnace and measurement table is used to prepare thick-film combinatorial libraries. Implementation of series of screening tests for ceramic inks that address stability against sedimentation, evaporation and particle segregation during drying, has provided a series of calibration inks can be used for calibration of this printer. The instrument can assemble ceramic mixtures with compositional accuracy of 1-3 wt %. By changing the amount of dispersant used in the inks or by printing onto a porous substrate, the geometry of residues from dried ceramic ink droplets can be modified to facilitate property measurements and uniform composition, as planned, can be achieved. The same material prepared in three ways, in the form of dried ink, ink-jet printed as for a combinatorial sample and by conventional compaction gave similar dielectric measurements. A combinatorial system has been developed so that combinatorial libraries can be printed, fired and screened automatically. A ternary A1203-TiO2-ZrO2 system was first studied using the developed combinatorial method. The particle segregation during drying of multi-component ceramic ink drops is not due to preferential sedimentation unless dispersant addition is restricted. The segregation is due to the partitioning of particles between the growing peripheral 'foot' that develops during drying and the diminishing liquid pool which contains vigorous recirculation flows. Better dispersed particles remain in the pool and hence are found in excess on the upper surface of residues. Less well dispersed particles join the 'foot' earlier in the drying process. The contact angle and height of droplets containing large amounts of dispersant, steadily reduced during drying until a minimum value was reached; the contact diameter being almost unchanged during drying. These droplet residues retained a dome shape. Droplets of suspensions containing small additions of dispersant terminated in a 'doughnut' shaped residue

Registration accuracy of the optical navigation system for image-guided surgery

Abstract. During the last decades, image-guided surgery has been a vastly growing method during medical operations. It provides a new opportunity to perform surgical operations with higher accuracy and reliability than before. In image-guided surgery, a navigation system is used to track the instrument’s location and orientation during the surgery. These navigation systems can track the instrument in many ways, the most common of which are optical tracking, mechanical tracking, and electromagnetic tracking. Usually, the navigation systems are used primarily in surgical operations located in the head and spine area. For this reason, it is essential to know the registration accuracy and thus the navigational accuracy of the navigation system, and how different registration methods might affect them. In this research, the registration accuracy of the optical navigation system is investigated by using a head phantom whose coordinate values of holes in the surface are measured during the navigation after different registration scenarios. Reference points are determined using computed tomography images taken from the head phantom. The absolute differences of the measured points to the corresponding reference points are calculated and the results are illustrated using bar graphs and three-dimensional point clouds. MATLAB is used to analyze and present the results. Results show that registration accuracy and thus also navigation accuracy are primarily affected by how the first three registration points are determined for the navigation system at the beginning of the registration. This should be considered in future applications where the navigation system is used in image-guided surgery.Kuvaohjatun kirurgian optisen navigointilaitteen rekisteröintitarkkuus. Tiivistelmä. Viimeisten vuosikymmenien aikana kuvaohjattu kirurgia on yleistynyt laajalti lääketieteellisten toimenpiteiden aikana ja se tarjoaa entistä paremman mahdollisuuden tarkkaan ja luotettavaan hoitoon. Kuvaohjatussa kirurgiassa navigointilaitteisto seuraa käytetyn instrumentin paikkaa ja orientaatiota operaation aikana. Navigointilaitteistoilla on erilaisia toimintaperiaatteita, joiden perusteella ne seuraavat instrumenttia. Yleisimmin käytetyt navigointilaitteistot perustuvat optiseen, mekaaniseen, tai sähkömagneettiseen seurantaan. Yleensä kuvaohjattua kirurgiaa käytetään pään ja selkärangan alueen kirurgisissa operaatioissa, joten on erittäin tärkeää, että navigointilaitteiston rekisteröinti- ja siten myös navigointitarkkuus tunnetaan, sekä erilaisten rekisteröintitapojen mahdolliset vaikutukset kyseisiin tarkkuuksiin. Tässä tutkimuksessa optisen navigointilaitteen rekisteröintitarkkuutta tutkitaan päämallin avulla, jonka pintaan luotujen reikien koordinaattiarvot mitataan navigointitilanteessa erilaisten rekisteröintitapojen jälkeen. Referenssipisteet kyseisille mittauspisteille määritetään päämallin tietokonetomografiakuvista. Mitattujen pisteiden, sekä vastaavien referenssipisteiden väliset absoluuttiset erot lasketaan ja tulokset esitetään palkkikuvaajien, sekä kolmiulotteisten pistepilvien avulla käyttäen apuna MATLAB-ohjelmistoa. Tulokset osoittavat, että rekisteröintitarkkuuteen ja siten navigointitarkkuuteen vaikuttaa eniten rekisteröintitilanteen alussa määritettävien kolmen ensimmäisen rekisteröintipisteen sijainti ja tämä tuleekin ottaa huomioon jatkossa tilanteissa, joissa navigointilaitetta käytetään kuvaohjatussa kirurgiassa

3D Printing: The Dawn of a New Era in Manufacturing

Printing is a process for reproducing text and images, typically with ink on paper using a print press.3D printing is method of converting a virtual 3D model into a physical object from a digital file. It is achieved using Additive Process, where an object is created by laying down successive layers of material until the entire object is created.3D printing could revolutionize and reshape the world. Advances in 3D printing technology can significantly change and improve the manufacturing world with effects on energy use, waste reduction, customization, product availability, medicine, art, construction and science. By using this technology it becomes easier to transmit designs for new objects around the world

Acquisition and reconstruction of 3D objects for robotic machining

With the evolution of the techniques of acquisition of Three-Dimensional (3D) image it became possible to apply these in more and more areas, as well as to be used for research and hobbyists due to the appearance of low cost 3D scanners. Among the application of 3D acquisitions is the reconstruction of objects, which allows for example to redo or remodel an existing object that is no longer on the market. Another rise tech is industrial robot, that is highly present in the industry and can perform several tasks, even machining activities, and can be applied in more than one type of operation. The purpose of this work is to acquire a 3D scene with low-cost scanners and use this acquisition to create the tool path for roughing a workpiece, using an industrial robot for this machining task. For the acquisition, the Skanect software was used, which had satisfactory results for the work, and the exported file of the acquisition was worked on the MeshLab and Meshmixer software, which were used to obtain only the interest part for the milling process. With the defined work object, it was applied in Computer Aided Manufacturing (CAM) software, Fusion 360, to generate the tool path for thinning in G-code, which was converted by the RoboDK software to robot code, and this also allowed to make simulation of the machining with the desired robot. With the simulation taking place as expected, it was implemented in practice, performing the 3D acquisition machining, thus being able to verify the machining technique used. Furthermore, with the results of acquire, generation of toolpath and machining, was possible to validate the proposed solution and reach a conclusion of possible improvements for this project.Com a evolução das técnicas de aquisição de imagem 3D tornou-se possível aplicá-las em cada vez mais áreas, bem como serem utilizadas por pesquisadores e amadores devido ao surgimento de scanners 3D de baixo custo. Entre as aplicações de aquisições 3D está a reconstrução de objetos, o que permite, por exemplo, refazer ou remodelar um objeto existente que não está mais no mercado. Outra tecnologia em ascensão é o robô industrial, que está muito presente na indústria e pode realizar diversas tarefas, até mesmo atividades de fabrico, e ser aplicado em mais de um tipo de operação. O objetivo deste trabalho é adquirir uma cena 3D com scanners de baixo custo e utilizar esta aquisição para criar o caminho da ferramenta para o desbaste de uma peça, utilizando um robô industrial nesta tarefa de usinagem. Para a aquisição foi utilizado o software Skanect, que obteve resultados satisfatórios para o trabalho, e o arquivo exportado da aquisição foi trabalhado nos softwares MeshLab e Meshmixer, os quais foram utilizados para obter apenas a parte de interesse para o processo de fresagem. Com o objeto de trabalho defino, este foi aplicado em software CAM, Fusion 360, para gerar o caminho de ferramentas para o desbaste em G-code, o qual foi convertido pelo Software RoboDK para código de rôbo, e este também permitiu fazer simulação da maquinação com o rôbo pretendido. Com a simulação ocorrendo de acordo com o esperado, esta foi implementada em prática, realizando a maquinação da aquisição 3D, assim podendo verificar a técnica de maquinação utilizada. Além disso com os resultados de aquisição, geração de toolpath e maquinação, foi possível validar a solução proposta e chegar a uma conclusão de possíveis melhorias para este projeto

Mars: The Viking discoveries

An overview of the Viking Mars probe is presented. The Viking spacecraft is described and a brief history of the earlier observations and exploration of Mars is provided. A number of the Viking photographs of the Martian surface are presented and a discussion of the experiments Viking performed including a confirmation of the general theory of relativity are reported. Martian surface chemistry is discussed and experiments to study the weather on Mars are reported