EFAB: Batch Production of Functional, Fully-Dense Metal Parts with Micron-Scale Features

EFAB (Electrochemical FABrication) is a new SFF process with the potential to economically fabricate prototypes or mass production quantities of functional, mesoscale-microscale parts and mechanisms. EFAB generates an entire layer simultaneously-versus serially, as with most SFF. Based on electrodeposition, EFAB allows ultra-thin layers (2-10 microns, or even submicron) that minimize stairsteps, and generates a net-shape, fully-dense metal structure that can be homogeneous and isotropic. Minimum feature width is approximately 25 microns, and can be reduced further. EFAB can be used to manufacture micromachines and microelectromechanical systems (MEMS), offering significant advantages over current processes: e.g., true 3-D geometry, IC compatibility, low capital investment, and process automation.Mechanical Engineerin

Revealing the Deposition Mechanism of the Powder Aerosol Deposition Method Using Ceramic Oxide Core–Shell Particles

The powder aerosol deposition (PAD) method is a process to manufacture ceramic films completely at room temperature. Since the first reports by Akedo in the late 1990s, much research has been conducted to reveal the exact mechanism of the deposition process. However, it is still not fully understood. This work tackles this challenge using core–shell particles. Two coated oxides, Al2O3 core with a SiO2 shell and LiNi0.6Mn0.2Co0.2O2 core with a LiNbO3 shell, are investigated. Initially, the element ratios Al:Si and Ni:Nb of the powder are determined by energy-dispersive X-ray spectroscopy (EDX). In a second step, the change in the element ratios of Al:Si and Ni:Nb after deposition is investigated. The element ratios from powder to film strongly shift toward the shell elements, indicating that the particles fracture and only the outer parts of the particles are deposited. In the last step, this work investigates cross-sections of the deposited films with scanning transmission electron microscopy (STEM combined with EDX and an energy-selective back-scattered electron (EsB) detector to unveil the element distribution within the film itself. Therefore, the following overall picture emerges: particles impact on the substrate or on previously deposited particle, fracture, and only a small part of the impacting particles that originate from the outer part of the impacting particle gets deposited

Soft Robotics with Variable Stiffness Actuators: Tough Robots for Soft Human Robot Interaction

Robots that are not only robust, dynamic, and gentle in the human robot interaction, but are also able to perform precise and repeatable movements, need accurate dynamics modeling and a high-performance closed-loop control. As a technological basis we propose robots with intrinsically compliant joints, a stiff link structure, and a soft shell. The flexible joints are driven by Variable Stiffness Actuators (VSA) with a mechanical spring coupling between the motor and the actuator output and the ability to change the mechanical stiffness of the spring coupling. Several model based and model free control approaches have been developed for this technology, e.g. Cartesian stiffness control, optimal control, reactions, reflexes, and cyclic motion control