Exploring Vacuum Casting Techniques for Micron and Submicron Features

A study of resolution limits in standard rapid prototyping vacuum cast molding processes and adaptation of this technique to reach submicron accuracy is proposed. Micro-fabrication technologies are used to fabricate micron and submicron high aspect-ratio patterns on the original parts. The molding of the original parts is optimized to allow replication of submicron features. In carefully exploring materials and surface treatments, cast parts are successfully replicated with submicron and high aspect ratio micron structures. These encouraging results enable the use of such processes for micro- and nano-systems applications and open the door to development and production of low cost, high resolution biochips.Mechanical Engineerin

Prototyping a process-centered environment

This paper describes an experimental system developed and used as a vehicle for prototyping the Arcadia-1 software development environment. Prototyping is viewed as a knowledge acquisition process and is used to reduce risks in software development by gaining rapid feedback about the suitability of a production system before the system is completed. Prototyping a software development environment is particularly important due to the lack of experience with them. There is an acute need to acquire knowledge about user interaction requirements for software environments. These needs are especially important for the Arcadia project, as it is one of the first attempts to construct a process-centered environment. Our prototyping effort addresses questions about effective interaction with a process-centered environment by simulating how Arcadia-1 would interact with users in a representative range of usage scenarios. We built a prototyping system, called PRODUCER, and used it to generate a variety of prototypes simulating user interactions with Arcadia-1 process programs.Experience with PRODUCER indicates that our approach is effective at risk reduction. The prototypes greatly improved communication with our customer. They confirmed some of our design decisions but also redirected our research efforts as a result of unexpected insight. We also found that prototyping usage scenarios provides conceptual guides and design information for process programmers. Most of the benefits of our prototyping effort derive from developing and interacting with usage scenarios, so our approach is generalizable to other prototyping systems. This paper reports on our prototyping approach and our experience in prototyping a process-centered environment

Microscale Freeform Integration by Directed Self Assembly

Most solid freeform fabrication (SFF) manufacturing processes assemble uniform components such as powder particles or polymer chains to produce desired geometries. Their capacity for producing highly functional parts (integrated actuation, sensing, and electronics) will dramatically increase when multiple materials and functional subcomponents can be automatically integrated. This paper addresses criteria for a system that integrates multiple materials and components through computer-controlled self-assembly. It builds complex systems from layers of self-assembled micro-components. The paper will address implementation methods, present a concept demonstration, and consider its application to micro-thermoelectric systems. This manufacturing process can be enhanced further through integration with mature additive processes.Mechanical Engineerin

A Film Fabrication Process on Transparent Substrate using Mask Projection Micro-Stereolithography

In this study, a Mask Projection Micro-Stereolithography (MPµSLA) process with the ability to cure a film of various thicknesses on transparent substrates is presented. Incident radiation, patterned by a dynamic mask, passes through a transparent substrate to cure photopolymer resin layers that grow progressively from the substrate surface. When compared to existing Stereolithography techniques, this technique eliminates the necessity of recoating, reducing process time and improving accuracy. A film of varying thicknesses can be fabricated on flat or curved transparent substrates. Models of the optical system and resin cure are developed and reported. An existing MPµSLA process planning method is being extended to account for radiation transmission through a substrate. The models are verified using experiments.Mechanical Engineerin

Toward mass production of microtextured microdevices: linking rapid prototyping with microinjection molding

The possibility of manufacturing textured materials and devices, with surface properties controlled from the design stage, instead of being the result of machining processes or chemical attacks, is a key factor for the incorporation of advanced functionalities to a wide set of micro and nanosystems. Recently developed high-precision additive manufacturing technologies, together with the use of fractal models linked to computer-aided design tools, allow for a precise definition and control of final surface properties for a wide set of applications, although the production of larger series based on these resources is still an unsolved challenge. However, rapid prototypes, with controlled surface topography, can be used as original masters for obtaining micromold inserts for final large-scale series manufacture of replicas using microinjection molding. In this study, an original procedure is presented, aimed at connecting rapid prototyping with microinjection molding, for the mass production of two different microtextured microsystems, linked to tissue engineering tasks, using different thermoplastics as ultimate materials

Rapid prototyping of multi-scale biomedical microdevices by combining additive manufacturing technologies

The possibility of designing and manufacturing biomedical microdevices with multiple length-scale geometries can help to promote special interactions both with their environment and with surrounding biological systems. These interactions aim to enhance biocompatibility and overall performance by using biomimetic approaches. In this paper, we present a design and manufacturing procedure for obtaining multi-scale biomedical microsystems based on the combination of two additive manufacturing processes: a conventional laser writer to manufacture the overall device structure, and a direct-laser writer based on two-photon polymerization to yield finer details. The process excels for its versatility, accuracy and manufacturing speed and allows for the manufacture of microsystems and implants with overall sizes up to several millimeters and with details down to sub-micrometric structures. As an application example we have focused on manufacturing a biomedical microsystem to analyze the impact of microtextured surfaces on cell motility. This process yielded a relevant increase in precision and manufacturing speed when compared with more conventional rapid prototyping procedures

Rapid fabrication of polymer microfluidic systems for the production of artificial lipid bilayers

A polymer microfluidic device has been fabricated using rapid prototyping techniques. The device was built up to allow the formation and subsequent investigation of artificial bilayer lipid membranes (BLMs). A simple dry film photoresist stamp was used to hot emboss microfluidic channels into PMMA films. Laser micromachining was employed to form an aperture into PMMA films. Laser micromachining was employed to form an aperture through the PMMA channels, across which the BLM was later formed. The dry film phororesist was also used as a simple etch mask for the deep etching of glass substrates in buffered HF solutions, which was used in this work for the production of glass embossing stamps. We show that bilayer films can be successfully produced across laser micromachined apertures in PMMA films

Quantifying Dimensional Accuracy of a Mask Projection Micro Stereolithography System

Mask Projection Microstereolithography is capable for fabricating true three-dimensional microparts and hence, holds promise as a potential micro-fabrication process for micro-machine components. In this paper, the Mask Projection Micro-Stereolithography (MPµSLA) system developed at the Rapid Prototyping and Manufacturing Institute at Georgia Institute of Technology is presented. The dimensional accuracy of the system is improved by reducing its process planning errors. To this effect, the MPµSLA process is mathematically modeled. In this paper, the irradiance received by the resin surface is modeled as a function of the imaging system parameters and the pattern displayed on the dynamic mask. The resin used in the system is characterized to experimentally determine its working curve. This work enables us to compute the dimensions of a single layer cured using our system. The analytical model is validated by curing test layers on the system. The model computes layer dimensions within 5% error.Mechanical Engineerin

Computer-Assisted Prototyping of Advanced Microsystems

Contains reports on five research projects.Defense Advanced Research Projects Agency Contract DABT 63-95-C-0088Stanford Universit

Semi-automated creation of converged iTV services: From macromedia director simulations to services ready for broadcast

While sound and video may capture viewers’ attention, interaction can captivate them. This has not been available prior to the advent of Digital Television. In fact, what lies at the heart of the Digital Television revolution is this new type of interactive content, offered in the form of interactive Television (iTV) services. On top of that, the new world of converged networks has created a demand for a new type of converged services on a range of mobile terminals (Tablet PCs, PDAs and mobile phones). This paper aims at presenting a new approach to service creation that allows for the semi-automatic translation of simulations and rapid prototypes created in the accessible desktop multimedia authoring package Macromedia Director into services ready for broadcast. This is achieved by a series of tools that de-skill and speed-up the process of creating digital TV user interfaces (UI) and applications for mobile terminals. The benefits of rapid prototyping are essential for the production of these new types of services, and are therefore discussed in the first section of this paper. In the following sections, an overview of the operation of content, service, creation and management sub-systems is presented, which illustrates why these tools compose an important and integral part of a system responsible of creating, delivering and managing converged broadcast and telecommunications services. The next section examines a number of metadata languages candidates for describing the iTV services user interface and the schema language adopted in this project. A detailed description of the operation of the two tools is provided to offer an insight of how they can be used to de-skill and speed-up the process of creating digital TV user interfaces and applications for mobile terminals. Finally, representative broadcast oriented and telecommunication oriented converged service components are also introduced, demonstrating how these tools have been used to generate different types of services