Computer-Aided Geometry Modeling

Techniques in computer-aided geometry modeling and their application are addressed. Mathematical modeling, solid geometry models, management of geometric data, development of geometry standards, and interactive and graphic procedures are discussed. The applications include aeronautical and aerospace structures design, fluid flow modeling, and gas turbine design

Computer-Generated Holography for Areal Additive Manufacture

With a market of approximately $10B, additive manufacture (AM) is an exciting next-generation technology with the promise of significant environmental and societal impact. AM promises to help reduce emissions and waste during manufacture while improving sustainability. Widely used in applications from hip implants to jet engines, AM remains the domain of experts due to the material and thermal challenges encountered. AM in metals is dominated by Laser Powder Based Fusion (L-PBF). Powder is spread in layers 10s of microns thick and selectively melted by scanning a small laser spot heat source over the bed. Traditional AM systems have limited ability to manage or compensate for heat generated. The rapidly moving heat source spot results in high thermal cycling and is a major influence on residual stress and distortion. Mechanical limitations in the galvoscanner mean that over or under-heating is common and can lead to voids, boiling and spatter. The scale difference between the part size and the spot size means that predictive modelling is beyond the scope of even today’s best computing clusters. These factors have led to frequent inability to ensure part quality without physical prototyping and destructive testing. This thesis sets out initial research into creating a radically new AM process that uses computer-generated holography (CGH) to produce complex light patterns in a single pulse. Projecting power to the whole layer at once will mean that the thermal properties of the powders before and after writing can be factored into the processed hologram and part design. It will also significantly reduce thermal gradients and melt-pool instability. The fields of additive manufacture and computer-generated holography are introduced in Chapter 1. Chapters 2 and 3 then provide more detail on CGH and AM modelling respectively. The first deliverable, a reusable software package capable of generating holograms, is presented in Chapter 4. Algorithms developed for the project are introduced in Chapter 4.3. The first project demonstrator, an AM machine capable of printing in resins using holographic projection is discussed in Section 6.2. This shows performance comparable to modern 3D printing machines and highlights the applicability of computer-generated holography to areal processes. Section 6.3 then discusses the ongoing development of a metal powder demonstrator. As this PhD forms the first stage of a larger project, only preliminary work on the powder demonstrator is discussed. Chapter 7 then draws conclusions and outlines the way forward for future research. The thesis appendices then discuss an in-depth discussion of algorithm performances in Appendices A and B. Appendices C and D then discuss digressions into the implementation. Appendices E and F present a laser induced damage threshold (LIDT) measurement system developed. Finally, Appendices G and H provide more detail on the software developed and Appendix I gives links to additional project resources.EP/T008369/1; EP/L016567/1; EP/V055003/

Multiscale methods for fabrication design

Thesis: Ph. D., Massachusetts Institute of Technology, Department of Electrical Engineering and Computer Science, 2018.This electronic version was submitted by the student author. The certified thesis is available in the Institute Archives and Special Collections.Cataloged from student-submitted PDF version of thesis.Includes bibliographical references (pages 135-146).Modern manufacturing technologies such as 3D printing enable the fabrication of objects with extraordinary complexity. Arranging materials to form functional structures can achieve a much wider range of physical properties than in the constituent materials. Many applications have been demonstrated in the fields of mechanics, acoustics, optics, and electromagnetics. Unfortunately, it is difficult to design objects manually in the large combinatorial space of possible designs. Computational design algorithms have been developed to automatically design objects with specified physical properties. However, many types of physical properties are still very challenging to optimize because predictive and efficient simulations are not available for problems such as high-resolution non-linear elasticity or dynamics with friction and impact. For simpler problems such as linear elasticity, where accurate simulation is available, the simulation resolution handled by desktop workstations is still orders of magnitudes below available printing resolutions. We propose to speed up simulation and inverse design process of fabricable objects by using multiscale methods. Our method computes coarse-scale simulation meshes with data-drive material models. It improves the simulation efficiency while preserving the characteristic deformation and motion of elastic objects. The first step in our method is to construct a library of microstructures with their material properties such as Young's modulus and Poisson's ratio. The range of achievable material properties is called the material property gamut. We developed efficient sampling method to compute the gamut by focusing on finding samples near and outside the currently sampled gamut. Next, with a pre-computed gamut, functional objects can be simulated and designed using microstructures instead of the base materials. This allows us to simulate and optimize complex objects at a much coarser scale to improve simulation efficiency. The speed improvement leads to designs with as many as a trillion voxels to match printer resolutions. It also enables computational design of dynamic properties that can be faithfully reproduced in reality. In addition to efficient design optimization, the gamut representation of the microstructure envelope provides a way to discover templates of microstructures with extremal physical properties. In contrast to work where such templates are constructed by hand, our work enables the first computational method to automatically discovery microstructure templates that arise from voxel representations.by Desai Chen.Ph. D

ID Photograph hashing : a global approach

This thesis addresses the question of the authenticity of identity photographs, part of the documents required in controlled access. Since sophisticated means of reproduction are publicly available, new methods / techniques should prevent tampering and unauthorized reproduction of the photograph. This thesis proposes a hashing method for the authentication of the identity photographs, robust to print-and-scan. This study focuses also on the effects of digitization at hash level. The developed algorithm performs a dimension reduction, based on independent component analysis (ICA). In the learning stage, the subspace projection is obtained by applying ICA and then reduced according to an original entropic selection strategy. In the extraction stage, the coefficients obtained after projecting the identity image on the subspace are quantified and binarized to obtain the hash value. The study reveals the effects of the scanning noise on the hash values of the identity photographs and shows that the proposed method is robust to the print-and-scan attack. The approach focusing on robust hashing of a restricted class of images (identity) differs from classical approaches that address any imageCette thèse traite de la question de l’authenticité des photographies d’identité, partie intégrante des documents nécessaires lors d’un contrôle d’accès. Alors que les moyens de reproduction sophistiqués sont accessibles au grand public, de nouvelles méthodes / techniques doivent empêcher toute falsification / reproduction non autorisée de la photographie d’identité. Cette thèse propose une méthode de hachage pour l’authentification de photographies d’identité, robuste à l’impression-lecture. Ce travail met ainsi l’accent sur les effets de la numérisation au niveau de hachage. L’algorithme mis au point procède à une réduction de dimension, basée sur l’analyse en composantes indépendantes (ICA). Dans la phase d’apprentissage, le sous-espace de projection est obtenu en appliquant l’ICA puis réduit selon une stratégie de sélection entropique originale. Dans l’étape d’extraction, les coefficients obtenus après projection de l’image d’identité sur le sous-espace sont quantifiés et binarisés pour obtenir la valeur de hachage. L’étude révèle les effets du bruit de balayage intervenant lors de la numérisation des photographies d’identité sur les valeurs de hachage et montre que la méthode proposée est robuste à l’attaque d’impression-lecture. L’approche suivie en se focalisant sur le hachage robuste d’une classe restreinte d’images (d’identité) se distingue des approches classiques qui adressent une image quelconqu

Fabrication, Mechanical Characterization, and Modeling of 3D Architected Materials upon Static and Dynamic Loading

Architected materials have been ubiquitous in nature, enabling unique properties that are unachievable by monolithic, homogeneous materials. Inspired by natural processes, man-made three-dimensional (3D) architected materials have been reported to enable novel mechanical properties such as high stiffness- and strength-to-density ratios, extreme resilience, or high energy absorption. Furthermore, advanced fabrication techniques have enabled architected materials with feature sizes at the nanometer-scale, which exploit material size effects to approach theoretical bounds. However, most architected materials have relied on symmetry, periodicity, and lack of defects to achieve the desired mechanical response, resulting in sub-optimal mechanical response under the presence of inevitable defects. Additionally, most of these nano- and micro-architected materials have only been studied in the static regime, leaving the dynamic parameter space unexplored. In this work, we address these issues by: (i) proposing numerical and theoretical tools that predict the behavior of architected materials with non-ideal geometries, (ii) presenting a pathway for scalable fabrication of tunable nano-architected materials, and (iii) exploring the response of nano- and micro-architected materials under three types of dynamic loading. We first explore lattice architectures with features at the micro- and millimeter scales and provide an extension to the classical stiffness scaling laws, enabled by reduced-order numerical models and experiments at both scales. After discussing the effect of nodes (i.e., junctions) on the mechanical response of lattice architectures, we propose alternative node-less geometries that eliminate the stress concentrations associated with nodes to provide extreme resilience. Using natural processes such as spinodal decomposition, we present pathways to fabricate a version of these materials with samples sizes on the order of cubic centimeters while achieving feature sizes on the order of tens of nanometers. In the dynamic regime, we design, fabricate, and test micro-architected materials with tunable vibrational band gaps through the use of architectural reconfiguration and local resonance. Lastly, we present methods to fabricate carbon-based materials at the nano- and centimeter scales and test them under supersonic impact and blast conditions, respectively. Our work provides explorations into pathways that could enable the use of nano- and micro-architected materials for applications that go beyond small-volume, quasi-static mechanical regimes.</p

Digital Craft | In Search of a Method of Personal Expression Within the Digital

Our relationship with the digital has fundamentally changed within the past decade. A mesh of outside interests have been efficiently folding themselves into our lives. These exist as either a legion of hosted “free” web services touting the promise of a new-found collective intimacy, or a set of tightly coupled IOT(Internet of Things) applications that are slowly being pulled away from our fully capable hardware—all causing us to rely heavily on a virtual infrastructure that demands to host our work and place us at arm’s length of tools that we no longer own or control. This new bargain includes a view into our work and habits so that we can be better understood, tokenized, categorized, mapped, and finally monetized. While many today may be OK with this relationship, I’ll be frank, it unsettles me. I believe something fundamental is lost in this unravelling long-distance relationship. This thesis is a response. It pushes for a more intimate connection with technology within the backdrop of digital design and its many processes. In The Craftsman, Richard Sennett writes: “Making is Thinking,” and in his text he explores the close relationship between head and hand for a small set of traditional craftsmen: a cook, a musician and a glass blower. To elevate the digital within today’s architectural practice, I feel its use must also be seen as craft. But how might a relationship between head and hand manifest itself? Is there some similarity in thinking between Sennett’s craftsmen and the processes of successful digital design? I propose to investigate the mechanisms of digital Making, and hence digital Thinking through three design problems, inspired by the works of Neri Oxman, deskriptiv, Michael Hansmeyer, as well as the methods of D’Arcy Thompson, Shinichi Maruyama, Pina Bausch, and Frei Otto. By mindfully observing my exploration of these from a digital perspective, I believe it will be possible to get a sense of what makes craft possible within this realm

Discontinuous Fiber Composites, Volume II

Discontinuous fiber-reinforced polymers have gained importance in transportation industries due to their outstanding material properties, lower manufacturing costs and superior lightweight characteristics. One of the most attractive attributes of discontinuous fiber-reinforced composites is the ease with which they can be manufactured in large numbers, using injection and compression molding processes. The main aim of this Special Issue is to collect various investigations focused on the processing of discontinuous fiber-reinforced composites and the effect that processing has on fiber orientation, fiber length and fiber density distributions throughout the final product. Papers presenting investigations on the effect that fiber configurations have on the mechanical properties of the final composite products and materials were welcome in the Special Issue. Researchers who model and simulate processes involving discontinuous fiber composites as well as those performing experimental studies involving these composites were welcomed to submit papers. The authors were encouraged to present new models, constitutive laws, and measuring and monitoring techniques to provide a complete framework on these groundbreaking materials and to facilitate their use in different engineering applications