Search results

Recently, the constrained surface projection stereolithography (SL) technology is gaining wider attention and has been widely used in the 3D printing industry. In constrained surface projection SL systems, the separation of a newly cured layer from the constrained surface is a historical technical barrier. It greatly limits printable size, process reliability and print speed. Moreover, over-large separation force leads to adhesion failures in manufacturing processes, causing broken constrained surface and part defects. Against this background, this paper investigates the formation of separation forces and various factors that affect the separation process in constrained surface projection SL systems.

A bottom-up projection SL testbed, integrated with an in-situ separation force measurement unit, is developed for experimental study. Separation forces under various manufacturing process settings and constrained surface conditions are measured in situ. Additionally, physical models are constructed by considering the liquid resin filling process. Experiments are conducted to investigate influences of manufacturing process settings, constrained surface condition and print geometry on separation forces.

Separation forces increase linearly with the separation speed. The deformation and the oxygen inhibition layer near the constrained surface greatly reduce separation forces. The printing area, area/perimeter ratio and the degree of porousness of print geometries have a combined effect on determining separation forces.

This paper studied factors that influence separation force in constrained surface SL processes. Constrained surface conditions including oxygen inhibition layer thickness, deformation and oxygen permeation capability were investigated, and their influences on separation forces were revealed. Moreover, geometric factors of printing layers that are significant on determining separation forces have been identified and quantified. This study on separation forces provides a solid base for future work on adaptive control of constrained surface projection SL processes.

One of the major concerns of the constrained-surface stereolithography (SLA) process is that the built-up part may break because of the force resulting from the pulling-up process. This resultant force may become significant if the interface mechanism between the two contact surfaces (i.e. newly cured layer and the bottom of the resin vat) produces a strong bonding between them. The purpose of this paper is to characterize the separation process between the cured part and the resin vat by adopting an appropriate and simple mechanics-based model that can be used to probe the pulling-up process.

In this paper, the time-histories of the pulling-up forces are measured using FlexiForce® force sensors. The experimental data are analyzed and used to estimate the constitutive parameters of the separation mechanism. Here, the separation mechanism is modeled based on the concept of cohesive zone model (CZM) that is well-studied in the field of fracture mechanics. By using the experimentally measured pulling-up force, this paper proposes a very efficient inverse technique to estimate the constitutive parameters for the CZM. The constitutive laws for the CZM facilitate in relating the separation force at the interface between the cured part and the resin vat in terms of the pulling-up velocity. Unlike work proposed earlier, computationally expensive full-scale finite element runs are not essential in the current work while estimating the required parameters of the constitutive laws. Instead, mechanics-based computationally efficient surrogate model is proposed to readily estimate these constitutive parameters.

Two constitutive laws are compared on the basis of their predictions of the separation force profile. Excellent match is obtained between the measured and the predicted separation force profiles.

This paper selects a suitable mechanics-based model that can characterize the separation process and proposes a computationally efficient scheme to estimate the required constitutive parameters. The proposed scheme can be used to reliably predict the separation force for the constrained-surface SLA process, leading to improved productivity and reliability of the SLA processes in fabricating the built-up parts.

This study aims to accurately simulate the tilting separation process of mask projection stereolithography (MPSL) and verify the tilting theory.

The finite element separation models of MPSL 3D printing process were established. The established models simulated both tilting and pulling-up separation process by changing the constraints and boundary conditions. The bilinear cohesive curves were used to define the separation interface. The stress distribution of the cured part and FEP film at different times during the whole separation process was extracted. Different orientations of pulling-up and tilting were also compared for stress distribution. The stress change was analyzed for the center and edge points of the upper surface of cured part.

The results showed that the stress increased with the separation speed, and the stress at the edge position of exposure area was greater than the internal position. The tilting traction stress distribution was affected by the exposure area function and the velocity distribution. Alternation of the exposure area function changed the cohesive stiffness. The non-coincidence of the calculated traction stress with the input bilinear cohesive curve reflected the influence of the material properties and the separation methods. The high-speed side of tilting had fast separation and high traction stress.

This study proposes a technical method for simulation tilting separation and verified the tilting theory. The cohesive zone model was proved applicable to the tilting traction stress calculation.

The purpose of this is to study the mechanism of an oil film thickness formation in the nanoscale. A polar lubricant of propylene carbonate is used as the intervening liquid between contiguous bodies in concentrated contacts. A pressure caused by the hydrodynamic viscous action in addition to the double-layer electrostatic force, van der Waals inter-molecular forces and solvation pressure owing to inter-surface forces is considered when calculating the ultrathin lubricating films.

Using the Newton–Raphson iteration technique applied for the convergence of the hydrodynamic pressure, a numerical solution has been ascertained.

The results show that, at separations beyond about five molecular diameters of the intervening liquid, the formation of a lubricant film thickness is governed by the combined effects of viscous action and surface force of an attractive van der Waals force and a repulsive double-layer force. At smaller separations below five molecular diameters of the intervening liquid, the effect of the solvation force is dominant in determining the oil film thickness.

This paper fulfils an identified need to study the behavior of polar lubricants in concentrated contacts in ultrathin conjunctions. The effect of the hydrodynamic action, electrostatic force and surface action of van der Waals and solvation forces is considered when calculating the lubricant oil film thickness.

The ever present need for the miniaturization of electronic assemblies has driven the size of passive components to as small as the 01005 package size. However, the packaging standards for these components are still under development. The purpose of this work is to report results from experiments designed to establish optimum process parameters, pad sizes and component clearances for the surface mounting of 01005 passive components.

The experiments were designed using MODDE, an experimental design software tool, and were carried out with both 01005 capacitors and resistors. All the assembled components were examined under microscope and judged according to industrial workmanship standards.

It was found that a viable solder paste printing process for the assembly of 01005 components can be achieved with a 75 μm thick stencil. Type 5 solder paste achieved a similar printing performance to type 4. Under the experimental conditions used, the optimum pad dimensions for the 01005 capacitors were 210 μm length, 220 μm width, 160 μm separation and for the resistors were 190 μm length, 220 μm width, 160 μm separation. The smallest component clearance to reliably avoid bridging was found to be 100 μm. A high placement force of 3.5 N was found to cause cracking of 01005 resistors.

From this work, a surface mount process for 01005 passive components is established and it is concluded that electronics packaging density can be increased through the assembly of these small components. In the near future, the widespread use of them will definitely facilitate a further reduction in the size of electronic assemblies, especially in handheld and portable devices.

The purpose of this paper is to present a mask‐image‐projection‐based stereolithography (MIP‐SL) process that can combine two base materials with various concentrations and structures to produce a solid object with desired material characteristics. Stereolithography is an additive manufacturing process in which liquid photopolymer resin is cross‐linked and converted to solid. The fabrication of digital material requires frequent resin changes during the building process. The process presented in this paper attempts to address the related challenges in achieving such fabrication capability.

A two‐channel system design is presented for the multi‐material MIP‐SL process. In such a design, a coated thick film and linear motions in two axes are used to reduce the separation force of a cured layer. The material cleaning approach to thoroughly remove resin residue on built surfaces is presented for the developed process. Based on a developed testbed, experimental studies were conducted to verify the effectiveness of the presented process on digital material fabrication.

The proposed two‐channel system can reduce the separation force of a cured layer by an order of magnitude in the bottom‐up projection system. The developed two‐stage cleaning approach can effectively remove resin residue on built surfaces. Several multi‐material designs have been fabricated to highlight the capability of the developed MIP‐SL process.

A proof‐of‐concept testbed has been developed. Its building speed and accuracy can be further improved. The tests were limited to the same type of liquid resins. In addition, the removal of trapped air is a challenge in the presented process.

This paper presents a novel and a pioneering approach towards digital material fabrication based on the stereolithography process. This research contributes to the additive manufacturing development by significantly expanding the selection of base materials in fabricating solid objects with desired material characteristics.

This paper aims to Separation and sorting of biological cells is desirable in many applications for analyzing cell properties, such as disease diagnostics, drugs delivery, chemical processing and therapeutics.

Acoustic energy-based bioparticle separation is a simple, viable, bio-compatible and contact-less technique using, which can separate the bioparticles based on their density and size, with-out labeling the sample particles.

Conventionally available bioparticle separation techniques as fluorescence and immunomagnetic may cause a serious threat to the life of the cells due to various compatibility issues. Moreover, they also require an extra pre-processing labeling step. Contrarily, label-free separation can be considered as an alternative solution to the traditional bio-particle separation methods, due to their simpler operating principles and lower cost constraints. Acoustic based particle separation methods have captured a lot of attention among the other reported label-free particle separation techniques because of the numerous advantages it offers.

This study tries to briefly cover the developments of different acoustic-based particle separation techniques over the years. Unlike the conventional surveys on general bioparticles separation, this study is focused particularly on the acoustic-based particle separation. The study would provide a comprehensive guide for the future researchers especially working in the field of the acoustics, in studying and designing the acoustic-based particle separation techniques.

The study insights a brief theory of different types of acoustic waves and their interaction with the bioparticles is considered, followed by acoustic-based particle separation devices reported till the date. The integration of acoustic-based separation techniques with other methods and with each other is also discussed. Finally, all major aspects like the approach, and productivity, etc., of the adopted acoustic particle separation methods are sketched in this article.

The purpose of this paper is to evaluate current simulation capabilities for thin film delamination on the basis of real test data as well as a contribution to its extension in order to partly substitute experimental investigations.

The proposed model consists of a formulation that describes the behaviour of the bulk material and an approach that introduces the film's delamination capability. An implicit finite element framework with a cohesive zone implementation is used and described in detail. The numerical results on the basis of the a priori identified material parameters are related to the experimental work. In order to capture the obvious peel speed dependency of these delamination processes, a viscoelastic cohesive formulation is introduced and compared with a pure separation rate dependent cohesive material in the second part of this contribution.

The performed numerical simulations show a good approximation of the experimental peel process. The extension in order to take time‐dependent effects into account is required for the simulation of such problems. In contrast with the pure rate‐dependent model, the presented consistent formulation of the cohesive part is able to cover the whole range of observed material phenomena.

Owing to the absence of suitable experimental single mode investigations of the sealed layer, the used cohesive material parameters are identified in relation to the pre‐existing experimental results. Furthermore, the resultant peel force has a constant value due to the assumed homogeneous cohesive material and therefore gives only a mean approximation of the experimental values at this stage of the investigation.

The numerical representation of such a thin film delamination process in relation to real experimental results shows the additional capabilities and the usability of the implicit finite element method with a cohesive zone implementation in a clear and illustrative way. The first proposed cohesive extension based on a rheological model shows the capability to cover the full range of time‐dependent interface layer behaviour.

A STUDY of the flow in the immediate neighbourhood of the surface of a wing or body has often provided an explanation of apparent inconsistencies in the evidence obtained from tests in different wind tunnels or from model and full scale experiments. It is of the highest importance in investigations of critical changes in aerodynamic forces such as occur when a wing stalls, of interference effects and of oscillatory motions caused wholly or partially by aerodynamic forces.

This paper aims to focus on the stochastic analysis of composite rotor blades with matrix cracking in forward flight condition.

The effect of matrix cracking and uncertainties are introduced to the aeroelastic analysis through the cross-sectional stiffness properties obtained using thin-walled beam formulation, which is based on a mixed force and a displacement method. Forward flight analysis is carried out using an aeroelastic analysis methodology developed for composite rotor blades based on the finite element method in space and time. The effects of matrix cracking are introduced through the changes in the extension, extension-bending and bending matrices of composites, whereas the effect of uncertainties are introduced through the stochastic properties obtained from previous experimental and analytical studies.

The stochastic behavior of helicopter hub loads, blade root forces and blade tip responses are obtained for different crack densities. Further, assuming the behavior of progressive damage in same beam is measurable as compared to its undamaged state, the stochastic behaviors of delta values of various measurements are studied. From the stochastic analysis of forward flight behavior of composite rotor blades at various matrix cracking levels, it is observed that the histograms of these behaviors get mixed due to uncertainties. This analysis brings out the parameters which can be used for effective prediction of matrix cracking level under various uncertainties.

The behavior is useful for the development of a realistic online matrix crack prediction system.

Instead of introducing the white noise in the simulated data for testing the robustness of damage prediction algorithm, a systematic approach is developed to model uncertainties along with damage in forward flight simulation.