Shape Deposition Manufacturing Overview, examples, and its future

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Shape Deposition Manufacturing Overview,
examples, and its future

• March 2003 Gdansk, Poland
• Motohide Hatanaka
• Center for Design Research
• Stanford University, USA

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http//www.lib.utexas.edu/maps/world.html http//w
ww.geneve-tourisme.ch/ http//www.jnto.go.jp/eng/R
TG/RI/index.html
http//www.u-tokyo.ac.jp/ http//www.stanford.edu/
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Design and fabrication of insect-inspired robots
by shape deposition manufacturing
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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
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Limitations of commonrapid prototyping methods

• Material variation
• Functionality of the product
• Fabrication tolerance
• Requires special equipment

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Why not add material in bulk and then selectively
remove?
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SDM advantages over common rapid prototyping
methods

• 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)

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SDM capabilities
Multi-material molding
Component embedding
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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)
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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.

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Biology is a target for complex integrated
structures manufacturing
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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.
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Selective deposition
Embedded component
Sacrificial material
Selective deposition
Partially embedded.
Cross-boundary embedded.
Selective deposition of part material
Selective deposition of sacrificial material
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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).
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Selective removal
Excessive deposition
Selective removal
Selective removal of part material
Selective removal of sacrificial material
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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.
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Material property alteration by post-processing
Material property alteration. E.g. by heat
treatment, light exposure, or material addition.
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Selective removal by photo-lithography
Example A small flexural hinge with embedded
electrical wires.
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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_at_cdr.stanford.edu