Automated Design and Prototyping of
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Automated Design and Prototyping of Macro and Micro Compliant Mechanisms.

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Automated Design and Prototyping of Macro and Micro Compliant Mechanisms

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Automated design and prototyping of macro and micro compliant mechanisms

Automated Design and Prototyping of

Macro and Micro Compliant Mechanisms

Compliant mechanism concept leads to a clean separation of design/modeling from manufacturing/assembly activities. The objective of this research is to provide a link between the two through efficient data translations and automated reverse engineering techniques.

Objectives

Optimal topology design of compliant mechanisms

Automatic image interpretation and creation of solid model from optimized topology image

Reverse engineering for microfabricated artifacts

Image processing for edge-extraction and object-finding

Writing IGES file for Pro-Engineer

Macro prototyping using Stratasys FDM 1650 rapid prototyping system

Micro prototyping using MCNC’s Multi-User-MEMS-Processes (MUMPs)

Automated metrology for a ceramic meso-scale machining


Automated design and prototyping of macro and micro compliant mechanisms

Performance

Specifications

Synthesis

Solution

Refined Design

Solution

Reverse Engineering

Meshed Model

for Analysis

Solid Model from

the Optimized

Device

CAD model from

the macro prototype

Design

Mask Layout

for Microfab.

Digital Format

for SFF or CNC

Refined

Prototype

Digital Interface

Macro

Prototype

Micro

Prototype

Solid model from

microscopic images

Fabrication/Prototyping

Design and Prototyping of Macro & Micro Compliant Mechanisms


Automated design and prototyping of macro and micro compliant mechanisms

Edge Extraction from 2-D Images

Image from the optical microscope

After edge extraction


Automated design and prototyping of macro and micro compliant mechanisms

Edge Extraction from 2-D Images

Image from the optical microscope

After edge extraction

The lack of sharp edges corresponding to the actual structure poses a challenge in extracting the correct topology.


Automated design and prototyping of macro and micro compliant mechanisms

Verification with Test Images

Extracted circular segments ported into Pro-E in IGES format

Test image with circular curves

Extracted line segments ported into Pro-E in IGES format

Test image with sharp edges


Automated design and prototyping of macro and micro compliant mechanisms

Experimental Set-up for Optical Imaging


Automated design and prototyping of macro and micro compliant mechanisms

From Fabricated MEMS Device to a Solid Model

Optical microscope image of a compliant micro crimper

After edge extraction

5 µm


Automated design and prototyping of macro and micro compliant mechanisms

From Fabricated MEMS Device

to a Solid Model (cont’d)

Extruded solid model ready for analysis

IGES model exported into Pro-E with line and arc segments


Automated design and prototyping of macro and micro compliant mechanisms

From Fabricated MEMS Device to a Solid Model (cont’d)

FDM prototype of compliant gripper

Unloaded configuration

Deformation under loading


Automated design and prototyping of macro and micro compliant mechanisms

From Optimized Compliant Topology Image to a Solid Model

Topology optimization does not give the shape precisely in both the “super structure” and “material density” approaches.

Designer’s intuition is needed to interpret the image and to obtain a manufacturable form.

Simple image processing is inadequate to capture the correct quantitative behavior of the optimized compliant topology.

Future Tasks

Use shape optimization to refine the topology image with stress and manufacturability constraints.

Combine image processing with shape optimization to automate the entire process.


Automated design and prototyping of macro and micro compliant mechanisms

From Optimized Compliant Topology Image to a Solid Model

Optimized compliant topology using material density design parameterization

IGES model with line and arc segments

Image processing, edge extraction, and object finding


Automated design and prototyping of macro and micro compliant mechanisms

From Optimized Compliant Topology Image to a Solid Model

Solid model ready for rapid prototyping and/or detailed 3-D analysis

Suitable flexibility is not obtained.


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