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<p dir="ltr">Due to the vast increase and versatility of Additive Manufacturing and 3D-printing, in this study, the mechanical behavior of implementing both continuous and short carbon fiber within Nylon and investigated for its effectiveness within additively manufactured prints. Here, 0.1wt% of pure nylon was combined with carbon nanotubes through both dry and heat mixing to determine the best method and used to create printable filaments. Compression, tensile and short beam shear (SBS) samples were created and tested to determine maximum deformation and were simulated using ANSYS and its ACP Pre tool. SEM imaging was used to analyze CNT integration within the nylon filament, as well as the fractography of tested samples. Experimental testing shows that compressive strength increased by 28%, and the average SBS samples increased by 8% with minimal impacts on the tensile strength. The simulated results for Nylon/CF tensile samples were compared to experimental results and showed that lower amounts of carbon fiber samples tend to have lower errors.</p>

[pt] As tecnologias de manufatura para desenvolvimento de produtos evoluíram exponencialmente com o contínuo avanço dos algoritmos matemáticos e das interfaces de softwares cada vez mais intuitivos. Esse binômio potencializou a atual revolução digital, na qual se destaca a tecnologia de impressão 3D. Essa tecnologia cada vez mais acessível possibilita que usuários possam desenvolver protótipos físicos e até mesmo produzir por conta própria produtos para o mercado consumidor, atividade até então exclusiva das indústrias de manufatura. Uma das principais barreiras do processo ainda é o desenvolvimento de arquivos tridimensionais digitais, tornando-se necessário um entendimento específico na combinação do meio virtual com o meio físico. A compreensão do processo fomenta as diversas possibilidades que a impressão 3D pode oferecer no desenvolvimento de produtos inovadores. Essa tecnologia revoluciona a forma como projetamos, produzimos e consumimos. Para essa dissertação, estudos de casos focados em combate de robôs, uma área específica da robótica, foram desenvolvidos de forma inovadora, com comprovada eficácia em atuação. / [en] Manufacturing technologies for product development have evolved exponentially with the continued advancement of mathematical algorithms and increasingly intuitive software interfaces. This binomial has potentiated the current digital revolution, in which 3D printing technology stands out. This increasingly accessible technology enables users to develop physical prototypes and even produce products for the consumer market, a previously unique activity in the manufacturing industries. One of the main barriers of the process is still the development of three-dimensional digital files, making it necessary a specific understanding in the combination of the virtual environment with the physical environment. Understanding the process fosters the many possibilities that 3D printing can offer in the development of innovative products. This technology revolutionizes the way we design, produce and consume. In this dissertation, case studies focused on robot combat, a specific area of robotics, were developed in an innovative way, with proven effectiveness in action.

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As additive manufacturing gains market potential as a mainstream process in various sectors of industry, there is a growing need for addressing environmental aspects of this technology and the materials associated with it. In this master thesis, comparative life cycle assessments (LCAs) from cradle to grave between the conventional products and 3D-printed alternatives made of wood-plastic composite (WPC) were conducted based on the ISO 14044:2006 standard. Environmental impacts of each product were quantified for 10 impact categories. The goal of the LCAs was to determine whether the use of the 3D-printed WPC products may suggest a sustainable alternative to the conventional ones. This master thesis presents three case studies in which comparative LCAs were carried out. The first two case studies are about storage compartments for trucks from Scania, and the third one is about ceiling boards from Veidekke. The results showed that,  in  all  case  studies,  the  3D-printed  WPC alternatives  would  have smaller environmental   impacts   compared   with   the   conventional   products. The   most significant difference was observed in the first two case studies because of the light- weighting effect. The alternatives showed 51%, 68% and 13% lower global warming potential  (GWP)  than  the conventional  products  in  each  case study,  respectively. However, the results of the cradle-to-gate LCAs suggested that the 3D-printed WPC alternative might cause greater environmental impact than the conventional products regarding some impact categories. Therefore, in the LCA context, the 3D-printed WPC alternatives would be much more beneficial to the environment compared with the conventional products, but theenvironmental benefits might be insignificant from the manufacturer’s perspective. / Eftersom   additive   tillverkningsteknik   ökar   marknadspotentialen   som   en vanlig process  inom  olika  industrisektorer,  finns  det  ett  växande  behov av att ta  itu  med miljöaspekterna av denna teknik och de material som är associerade med den. I detta examensarbete avhandling genomfördes jämförande livscykelanalys (LCA) från vagga till   grav   mellan   de konventionella   produkterna   och   3D-printade   alternativ   av träplastkomposit (WPC) baserat på ISO 14044: 2006-standarden. Miljöpåverkan av varje produkt kvantifierades för 10 miljöeffekter. Målet med LCA var att avgöra om användningen av de 3D-printade WPC-produkterna kan vara ett hållbart alternativ till de konventionella. Denna avhandling presenterar tre fallstudier där jämförande LCA utfördes. De två första fallstudierna handlar om förvaringsutrymmen för lastbilar från Scania, och den tredje om takskivor från Veidekke. Resultaten visade att de 3D- printade WPC- alternativen   i   alla   fallstudier   skulle   ha   mindre   miljöpåverkan   jämfört   med konventionella  produkter.  Den  mest signifikanta  skillnaden observerades  i  de  två första  fallstudierna  på  grund av  den  lägre  vikte viktningseffekten.  Alternativen visade   51%,   68%   och   13%   lägre   global uppvärmningspotential   (GWP)   än   de konventionella produkterna i respektive fallstudie. Emellertid föreslog resultaten av vaggan-till-grind-LCA   att   det   3D-printade   WPC-alternativet   kan   orsaka   större miljöpåverkan än de konventionella produkterna avseende vissa miljöeffekter. Därför,   i   LCA-sammanhang,   skulle   de   3D-printade   WPC-alternativen   vara mycket  mer  fördelaktiga  för  miljön  jämfört  med  konventionella produkter, men miljöfördelarna kan vara obetydliga ur tillverkarens perspektiv.

Quadrupedal robots are mobile robots with four limbs. Compared with other mobile robots, quadrupedal robots are more capable of moving in complex environment. Specifically, softquadrupedal robots have the limbs that are flexible and more compliant with the environmentthan that of rigid quadrupedal robots. This project is based on a previous work at KTH where a soft quadrupedal robot prototype was built. The first part of this project is to build a test rig, analyze the dynamics of the 3D printed soft continuum actuators and choose one configuration toachieve the best dynamics. The second part of this project is to build a soft quadrupedal robotand analyze the standing and walking performance. The mechanical and electrical structure ofthe robot are re-designed to reduce the weight. Furthermore, gait analyses are conducted toenable the robot to walk. Cost of transport is calculated to compare the efficiency of differentgaits. / Mobila robotar som har fyra lemmar kallas fyrbenta robotar. Jämfört med andra mobila robotarär fyrbenta robotar mer kapabla att röra sig i komplexa miljöer. Särskild de mjuka fyrbentarobotar, vars flexibla lemmar är mer kompatibla med miljön än dem av stela fyrbenta robotar. Det här projektet är baserat på ett tidigare arbete på KTH där prototypen av en mjuk fyrbentrobot byggdes. Den första delen av detta projekt är att bygga en provrigg, analysera dynamikenav det 3D-skrivna mjuka kontinuumställdon och välja den konfigurationen som har bästadynamiken. Den andra delen av detta projekt är att bygga en mjuk fyrbent robot och analyseradess stå- och gångprestation. Den mekaniska och elektriska strukturen av roboten designades omför att minska vikten. Vidare är gångs analyser genomförda för att möjliggöra robotens gång. Cost of transport (COT) är uträknat för att jämföra olika gångs effektivitet.

Aims Use of 3D printed models in Endodontics has been gaining popularity since the technology to create them became more affordable. Currently, there are no studies that evaluate the influence of 3D models on endodontic surgical treatment planning and on operator confidence. Therefore, aims of this study were to: (i) Determine whether the availability of a 3D printed analogue can influence treatment-planning and operator confidence; and, (ii) Assess which factors of operator confidence are influenced, if any. Materials and Methods Endodontists were asked to analyze a pre-selected CBCT scan of an endodontic surgical case and to answer a questionnaire that determined their surgical approach for that case. After 30 days, the same participants were asked to analyze again the same CBCT scan. This time however, a 3D printed model of the scan was made available to the participants and to perform a mock osteotomy on the model. The participants were then asked to respond to the same questionnaire that they responded to 30 days prior to determine if there would be any changes to their treatment plan. A new set of questions were added to the survey to evaluate the influence of the 3D printed model on participants’ confidence in performing endodontic surgery. The responses were statistically analyzed using Chi square test followed by either logistic or ordered regression analysis while adjusting for experience of participant. Adjustment for multiple comparison analysis was done using Bonferroni correction. Statistical significance was set at £0.005. Results Availability of the 3D printed model and the CBCT scan together resulted in statistically significant differences in the participants’ responses to their ability to clearly detect bone landmarks, accurately predict the location of osteotomy, and in determining the following: size of osteotomy, angle of instrumentation, involvement of critical structures in flap reflection and involvement of vital structures during curettage. In addition, the participants’ confidence in performing surgery was significantly higher versus having CBCT scans alone. There were no statistically significant changes with decisions on flap design and extent, visualizing critical structures, lesion size, injury to vital structures during osteotomy, the length of root that could be resected and the number of roots involved. Conclusions The availability of 3D printed models did not alter the participants’ surgical approach, but it significantly improved their confidence for endodontic microsurgery, which can be attributed to better visualization of anatomical structures.

South Sudan currently has the third largest refugee crisis around the globe, with over 3.7 million people being displaced from their homes due to ethnic and political civil war. Over 2 million of these refugees have been displaced from their home country, seeking asylum in refugee settlements that neighbor South Sudan. One of the most important needs within these settlements is adequate housing. Through polling and census data, it has been found that more than half of the refugees are living in dilapidated housing conditions, without any resources to make repairs. The average amount of time spent within these settlements is over a decade and is increasingly getting worse as more refugees enter these settlements. Due to the exponential technological advancements in 3D printing technology, using this form of construction could potentially address a situation within a refugee settlement. 3D printing technology could provide benefits due to its ability to produce housing units at a high rate, its ability to use clay aggregate soil as construction material, mimicking adobe brick housing found in Africa, and the ability to lower the need for labor within these settlements. This thesis will explore the idea of employing this technology within a refugee settlement, to test if it can appropriately balance the implementation of a high tech 21st century technology with the historic and cultural vernacular architecture found regionally throughout Africa. / Master of Architecture / The country of South Sudan currently is experiencing the third largest refugee crisis around the globe. Over 2.5 million refugees have fled their home country of South Sudan and are entering refugee settlements from neighboring countries. Due to the exponential increasing rate of refugees within these settlements, issues such as overcrowding and inadequate housing are afflicting the lives of everyone here. Typical houses in South Sudan consist of mud and adobe brick material known as "tukul huts". While these huts have remained the leading housing type for the past 2,000 years, these houses where not intended for addressing the common refugee crisis we are experience today. These huts require the period of months to construct and extensive physical labor. Given that the refugees are entering these settlements at an exponential rate, it is ineffective to approach housing construction in a traditional manner due to the time and effort it requires to keep up with the high demand. A possible way to address this concern, is by looking at other construction practices that could potentially supplement the traditional forms of erecting houses. Construction technology has advanced to the point where 3D printers can create life size structures that provide housing to individuals. This thesis will explore the idea of employing 3D printers into a South Sudanese refugee settlement, to see if it can adequately produce houses that provide shelter for the incoming refugees.

Polysiloxanes represent a unique class of synthetic polymers, employing a completely inorganic backbone structure comprised of repeating –(Si–O)n– 'siloxane' main chain linkages. This results in an assortment of diverse properties exclusive to the siloxane bond that clearly distinguish them from the –(C–C)n– backbone of purely organic polymers. Previous work has elucidated a methodology for fabricating flexible and elastic crosslinked poly(dimethyl siloxane) (PDMS) constructs with high Mc through a simultaneous crosslinking and chain-extension methodology. However, these constructs suffer the poor mechanical properties typical of lower molecular weight crosslinked siloxanes (e.g. modulus, tear strength, and strain at break). Filled PDMS networks represent another important class of elastomers in which fillers, namely silica and siloxane-based fillers, impart improved mechanical properties to otherwise weak PDMS networks. This work demonstrates that proper silicon-based reinforcing agent selection (e.g. siloxane-based MQ copolymer nanoparticles) and incorporation provides a synergistic enhancement to mechanical properties, whilst maintaining a low viscosity liquid composition, at high loading content, without the use of co-solvents or heating. Rheological analysis evaluates the viscosity while photorheology and photocalorimetry measurements evaluate rate and extent of curing of the various MQ-loaded formulations, demonstrating theoretical printability up to 40 wt% MQ copolymer nanoparticle incorporation. Dynamic mechanical analysis (DMA) and tensile testing evaluated thermomechanical and mechanical properties of the cured nanocomposites as a function of MQ loading content, demonstrating a 3-fold increase in ultimate stress at 50 wt% MQ copolymer nanoparticle incorporation. VP AM of the 40 wt% MQ-loaded, photo-active PDMS formulation demonstrates facile amenability of photo-active PDMS formulations with high MQ-loading content to 3D printing processes with promising results. PDMS polyureas represent an important class of elastomers with unique properties derived from the synergy between the nonpolar nature, unusual flexibility, and low glass transition temperature (Tg) afforded by the backbone siloxane linkages (-Si-O)n- of PDMS and the exceptional hydrogen bond ordering and strength evoked by the bidentate hydrogen bonding of urea. The work herein presents an improved melt polycondensation synthetic methodology, which strategically harnesses the spontaneous pyrolytic degradation of urea to afford a series of PDMS polyureas via reactions at high temperatures in the presence of telechelic amine-terminated oligomeric poly(dimethyl siloxane) (PDMS1.6k-NH2) and optional 1,3-bis(3-aminopropyl)tetramethyldisiloxane (BATS) chain extender. This melt polycondensation approach uniquely circumvents the accustomed prerequisite of isocyanate monomer, solvent, and metal catalysts to afford isocyanate-free PDMS polyureas using bio-derived urea with the only reaction byproduct being ammonia, a fundamental raw ingredient for agricultural and industrial products. As professed above, reinforcement of polysiloxane materials is ascertained via the incorporation of reinforcing fillers or nanoparticles (typically fumed silica) or blocky or segmented development of polymer chains eliciting microphase separation, in order to cajole the elongation potential of polysiloxanes. Herein, a facile approach is detailed towards the synergistic fortification of PDMS-based materials through a collaborative effort between both primary methods of polysiloxane reinforcement. A novel one-pot methodology towards the facile, in situ incorporation of siloxane-based MQ copolymer nanoparticles into segmented PDMS polyureas to afford MQ-loaded thermoplastic and thermoplastic elastomer PDMS polyureas is detailed. The isocyanate-free melt polycondensation achieves visible melt dispersibility of MQ copolymer nanoparticles (good optical clarity) and affords segmented PDMS polyureas while in the presence of MQ nanoparticles, up to 40 wt% MQ, avoiding post-polymerization solvent based mixing, the only other reported alternative. Incorporation of MQ copolymer nanoparticles into segmented PDMS polyureas provides significant enhancements to modulus and ultimate stress properties: results resemble traditional filler effects and are contrary to previous studies and works discussed in Chapter 2 implementing MQ copolymer nanoparticles into chemically-crosslinked PDMS networks. In situ MQ-loaded, isocyanate-free, segmented PDMS polyureas remain compression moldable, affording transparent, free-standing films. / Master of Science / Polysiloxanes, also referred to as 'silicones' encompass a unique and important class of polymers harboring an inorganic backbone. Polysiloxanes, especially poly(dimethyl siloxane) (PDMS) the flagship polymer of the family, observe widespread utilization throughout industry and academia thanks to a plethora of desirable properties such as their incredible elongation potential, stability to irradiation, and facile chemical tunability. A major complication with the utilization of polysiloxanes for mechanical purposes is their poor resistance to defect propagation and material failure. As a result polysiloxane materials ubiquitously observe reinforcement in some fashion: reinforcement is achieved either through the physical or chemical incorporation of a reinforcing agent, such as fumed silica, or through the implementation of a chemical functionality that facilitates reinforcement via phase separation and strong associative properties, such as hydrogen bonding. This research tackles polysiloxane reinforcement via both of these strategies. Facile chemical modification permits the construction PDMS polymer chains that incorporate hydrogen bonding motifs, which phase separate to afford hydrogen bond-reinforced phases that instill vast improvements to elastic behavior, mechanical and elongation properties, and upper-use temperature. Novel nanocomposite formulation through the incorporation of MQ nanoparticles (which observe widespread usage in cosmetics) facilitate further routes toward improved mechanical and elongation properties. Furthermore, with growing interest in additive manufacturing strategies, which permit the construction of complex geometries via an additive approach (as opposed to conventional manufacturing processes, which require subtractive approaches and are limited in geometric complexity), great interest lies in the capability to additively manufacture polysiloxane-based materials. This work also illustrates the development of an MQ-reinforced polysiloxane system that is amenable to conventional vat photopolymerization additive manufacturing: chemical modification of PDMS polymer chains permits the installation of UV-activatable crosslinking motifs, allowing solid geometries to be constructed from a liquid precursor formulation.

This master thesis report is focused on the development and study of a tendon driven soft actuator for use on the Honda Haru robot. The single degree of freedom actuator will be used to actuate the eyes of the robot. Motivating development of this new actuator is the operational safety of the robot. A soft continuum actuator can provide a higher level of inherent safety as compared with the currently used rigid actuator. After development, a factorial study of the developed actuator was performed in order to understand the effect of velocity, load and material hardness on the actuator motion. The results of this study show that the linearity, hysteresis and current draw of the actuator are all affected by varying material and velocity. No significant effect of actuator load was measured. Data-driven system identification of the actuator was later performed using polynomial models. A relative comparison of standard-, nonlinear- and adaptive ARX models showed that adaptive ARX is most suitable to capture the dynamics of the developed actuator under dynamic conditions. / Denna examesarbetesrapport täcker utveckling samt studie av ett 3d-utskrivet mjukt ställdon. Det vajerdrivna ställdonet är designat för att driva ögonrörelser på den sociala roboten HARU och utvecklingen motiverades av den ökade säkerhet som en mjuk och eftergivlig komponent kan ge robotens användare jämfört med den nuvarande stela mekanismen. Den utvecklade komponenten undersöktes sedan i två faser. Först utfördes en faktorstudie där rörelsehastighets, lastvikts samt materialhårdhets påverkan på ställdonets kinematik undersöktes. Resultaten från denna studie visar att linjäritet, hysteres samt strömförbrukning av det utvecklade ställdonet påverkas av rörelsehastighet samt materialets hårdhet. Ingen signifikant påverkan av lastvikt uppmättes. Utöver faktorstudien undersöktes även förmågan av olika polynomialmodeller att modellera ställdonet med god nogrannhet. Linjära, ickelinjära samt rekursiva linjära modeller utvecklades via systemidentifiering och deras prestanda jämfördes. Resultaten från detta visar att rekursiva linjära modeller är bäst lämpade för att modellera det utvecklade ställdonet under dynamiska förhållanden.