3D Printed Soft Robotic Hand

Soft robotics is an emerging industry, largely dominated by companies which hand mold their actuators. Our team set out to design an entirely 3D printed soft robotic hand, powered by a pneumatic control system which will prove both the capabilities of soft robots and those of 3D printing. Through research, computer aided design, finite element analysis, and experimental testing, a functioning actuator was created capable of a deflection of 2.17” at a maximum pressure input of 15 psi. The single actuator was expanded into a 4 finger gripper and the design was printed and assembled. The created prototype was ultimately able to lift both a 100-gram apple and a 4-gram pill, proving its functionality in two prominent industries: pharmaceutical and food packing

Design of an effective and timely product development process for medical devices

Effective product development process is one of the most critical issues facing medical devices manufacturing today. There is a need to search for ways to improve or solve the cross organization and company boundaries to enhance the faster release of new medical products to the market. This thesis presents an integrated set of perspectives on the process of new product development of medical devices with dual goals of achieving marketing speed and meet customer satisfaction. The Attribute Driven Specifications approach described in this thesis, is one of the most valuable tools in the approach to effective product development in medical devices. This thesis aims to promote effective management of product design and development of medical devices by addressing the inherent complexity and operational reality of the development process of medical devices. Also presented are approaches to product design and development employed by some successful medical device industries

SUPPORTING ENGINEERING DESIGN OF ADDITIVELY MANUFACTURED MEDICAL DEVICES WITH KNOWLEDGE MANAGEMENT THROUGH ONTOLOGIES

Medical environments pose a substantial challenge for engineering designers. They combine significant knowledge demands with large investment for new product development and severe consequences in the case of design failure. Engineering designers must contend with an often-chaotic environment to which they have limited access and familiarity, a user base that is difficult to engage and highly diverse in many attributes, and a market structure that often pits stakeholders against one another. As medical care in general moves towards personalized models and surgical tools towards less invasive options emerging manufacturing technologies in additive manufacturing offer significant potential for the design of highly innovative medical devices. At the same time however these same technologies also introduce yet more challenges to the design process. This dissertation presents a knowledge-based approach to addressing the existing and emerging challenges of medical device design. The approach aims to address these challenges using knowledge captured in a suite of modular ontologies modeling knowledge domains that must be considered in medical device design. These include ontologies for understanding clinical context, human factors, regulation, enterprise, and manufacturability. Together these ontologies support design ideation, knowledge capture, and design verification. These ontologies are subsequently used to formulate a comprehensive knowledge framework for medical device design, and to enable an innovative design process. Case studies analyzing the design of surgical tools in several medical specialties are used to assess the capabilities of this approach

Research on Layer Manufacturing Techniques at Fraunhofer

Within the German Fraunhofer-Gesellschaft, the Fraunhofer Alliance Rapid Prototyping unites the competences of 12 institutes in the field of solid freeform fabrication. Covered competences are virtual and computer-aided product planning methods and techniques, the development and integration of materials and processes for different industrial sectors. This paper presents actual research results on layer manufacturing within the Fraunhofer- Gesellschaft based on examples from Fraunhofer ILT »Laser Melting - Direct manufacturing of metal parts with unique properties«, Fraunhofer IFAM »ecoMold - A novel concept to produce molds for plastic injection molding and pressure die casting« and Fraunhofer IPT »Quick manufacture, repair and modification of steel molds using Controlled Metal Build Up (CMB)«.Mechanical Engineerin

Sound Analysis - An intelligent device produced with CAD and CNC machinery using Industrial design and product development methods

This Master Thesis will cover the development of the mechanics and design aspects for a new product innovation made for IPsense AB (at Lund Technical University and Ingvar Kamprad Design Center in Lund, Sweden). Due to the sensitivity of the project some information has been left out. The product is part of an IP-based network concept developed for analyzing sound in real time. The total concept also involves software solutions integrated with a sound analyzing interface. The task was to design and develop the mechanical parts for a new concept. The goal of the thesis was to develop a solution in how to mechanically and ecstatically design the optimum electronic housing that will cope with the technical specifications given being possible to manufacture in smaller series. The result offers a good balance within design, sound design and flexibility. To achieve this, the product design was made modular using CAD, produced with CNC-machines for a rapid production in small series. Looking at the current situation: - Which are the customer needs for such a product - What products exists in the marketplace Further on: - Research and analyze customer needs and design issues - Choose the best housing-solution for prototyping - Manufacture and test the prototypeSound Analysis An intelligent device produced with CAD and state of the art CNC machinery, using Industrial design and product development methods, made for analyzing environment sounds. This Master Thesis resulted in a new product inspired by the human ear. The test showed some remarkable increase of the sound gradient which would interest the client, IPsense to file for a patent

Survey on Additive Manufacturing, Cloud 3D Printing and Services

Cloud Manufacturing (CM) is the concept of using manufacturing resources in a service oriented way over the Internet. Recent developments in Additive Manufacturing (AM) are making it possible to utilise resources ad-hoc as replacement for traditional manufacturing resources in case of spontaneous problems in the established manufacturing processes. In order to be of use in these scenarios the AM resources must adhere to a strict principle of transparency and service composition in adherence to the Cloud Computing (CC) paradigm. With this review we provide an overview over CM, AM and relevant domains as well as present the historical development of scientific research in these fields, starting from 2002. Part of this work is also a meta-review on the domain to further detail its development and structure

A Survey of Smart Manufacturing for High-Mix Low-Volume Production in Defense and Aerospace Industries

Defense and aerospace industries usually possess unique high-mix low-volume production characteristics. This uniqueness generally calls for prohibitive production costs and long production lead-time. One of the major trends in advanced, smart manufacturing is to be more responsive and better readiness while ensuring the same or higher production quality and lower cost. This study reviews the state-of-the-art manufacturing technologies to solve these issues and previews two levels of flexibility, i.e., system and process, that could potentially reduce the costs while increasing the production volume in such a scenario. The main contribution of the work includes an assessment of the current solutions for HMLV scenarios, especially within the defense of aerospace sectors, and a survey of the current and potential future practices focusing on smart production process planning and flexible assembly plan driven by emerging techniques

Variable cavity volume tooling for high-performance resin infusion moulding

This article describes the research carried out by Warwick under the BAE Systems/EPSRC programme ‘Flapless Aerial Vehicles Integrated Interdisciplinary Research – FLAVIIR’. Warwick's aim in FLAVIIR was to develop low-cost innovative tooling technologies to enable the affordable manufacture of complex composite aerospace structures and to help realize the aim of the Grand Challenge of maintenance-free, low-cost unmanned aerial vehicle manufacture. This article focuses on the evaluation of a novel tooling process (variable cavity tooling) to enable the complete infusion of resin throughout non-crimp fabric within a mould cavity under low (0.1 MPa) injection pressure. The contribution of the primary processing parameters to the mechanical properties of a carbon composite component (bulk-head lug section), and the interactions between parameters, was determined. The initial mould gap (di) was identified as having the most significant effect on all measured mechanical properties, but complex interactions between di, n (number of fabric layers), and vc (mould closure rate) were observed. The process capability was low due to the manual processing, but was improved through process optimization, and delivered properties comparable to high-pressure resin transfer moulding

Microheater Array Powder Sintering (MAPS) for Printing Flexible Electronics

Microheater array powder sintering (MAPS) is a novel additive manufacturing process that uses an array of microheaters to selectively sinter powder particles. MAPS shows great promise as a new method of printing flexible electronics by enabling digital curing of conductive inks on a variety of substrates. MAPS operation relies on establishing a precision air gap of a few microns between an array of microheaters, which can reach temperatures of 600°C, and a layer of conductive ink which can be deposited onto a flexible substrate. This system presents challenges, being: the fabrication of a microheater that can reach suitable temperatures in an acceptable time frame and is reliable, electronic control of a single microheater, electronic control of an array of microheaters, and precise control of the position of the array of microheaters relative to the substrate. This work describes the design and fabrication of a printer which uses this novel technology to print flexible circuit boards. Various simulations are discussed which are used to explore the parameters affecting the MAPS printing process. Then, a small microheater array is fabricated and controlled using an electronic circuit using a PID feedback loop. This microheater array is used in an experimental proof of concept machine to print conductive lines onto a flexible substrate. Finally, a prototype MAPS printer is developed which is capable of using an improved microheater array to print simple circuits onto flexible substrates