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Shape Deposition Manufacturing Overview, examples, and its future

Shape Deposition Manufacturing Overview, examples, and its future. March 2003 Gdansk, Poland Motohide Hatanaka Center for Design Research Stanford University, USA. http://www.lib.utexas.edu/maps/world.html http://www.geneve-tourisme.ch/ http://www.jnto.go.jp/eng/RTG/RI/index.html.

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Shape Deposition Manufacturing Overview, examples, and its future

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  1. Shape Deposition ManufacturingOverview, examples, and its future March 2003 Gdansk, Poland Motohide Hatanaka Center for Design Research Stanford University, USA

  2. http://www.lib.utexas.edu/maps/world.html http://www.geneve-tourisme.ch/ http://www.jnto.go.jp/eng/RTG/RI/index.html http://www.u-tokyo.ac.jp/ http://www.stanford.edu/

  3. Design and fabrication of insect-inspired robots by shape deposition manufacturing

  4. Examples of rapid prototyping methods • Stereo Lithography • 3D Printing (http://www.mit.edu/~tdp/) • Selective Laser Sintering • Fuse Deposition Manufacturing Selective curing, bonding, sintering, or deposition in layers

  5. Remember! Selective curing, bonding, sintering, or deposition in layers Limitations of commonrapid prototyping methods • Material variation • Functionality of the product • Fabrication tolerance • Requires special equipment

  6. Why not add material in bulk and then selectively remove?

  7. Limited material variation Non-functional product Limited fabrication tolerance Requires special equipment Wide variety of materials Functional product Fabrication tolerance comparable to conventional machining Conventional machining tools used. Can embed parts (sensors, actuators, reinforcement) SDM advantages over commonrapid prototyping methods

  8. SDM capabilities Multi-material molding Component embedding

  9. Fabric-reinforced flexural hinges Left: Kinematic prototype of stroke extension linkage with 31 parts Center: Single component SDM linkage with thick flexures Right: SDM linkage with thin fabric-reinforced flexures (2001)

  10. SDM is suited for complex integration • Material properties can be locally altered by multi-material fabrication. • Components can be assembled without fasteners, hence easier and more room for complex integration. • Semi-automated process allows detailed fabrication.

  11. Biology is a target for complex integrated structures manufacturing

  12. Cross-boundary embedding Insert Material A Material B Challenge: Selectively adding, removing or otherwise processing material around the flexible strands without damaging them or being hindered by them.

  13. Selective deposition Embedded component Sacrificial material Selective deposition Partially embedded. Cross-boundary embedded. Selective deposition of part material Selective deposition of sacrificial material

  14. Capillary effect for selective deposition Example: Small string-suspended gimbals with two rotational degrees of freedom. Developed for attitude control of solar panels on a small satellite (100mm-side cube).

  15. Selective removal Excessive deposition Selective removal Selective removal of part material Selective removal of sacrificial material

  16. Manual Selective Removal Example: Spring-loaded hinge with partially embedded coil-spring and fiber-reinforced flexure. Developed for deploying solar-panels for a small satellite.

  17. Material property alteration by post-processing Material property alteration. E.g. by heat treatment, light exposure, or material addition.

  18. Selective removal by photo-lithography Example: A small flexural hinge with embedded electrical wires.

  19. What was SDM? Rapid production method with repetitive addition and selective removal of materials. It uses conventional machining facilities, hence also achieves the same order of machining tolerances. Multi-material parts can be created to compose functional mechanisms, also with embedded functional parts such as sensors and actuators. Cross-boundary embedding is the key for realizing highly integrated structures. http://www-cdr.stanford.edu/biomimetics Motohide Hatanaka: motohat@cdr.stanford.edu

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