Mass production and assembly lines are yesterday’s manufacturing methods. They have exhausted Earth’s resources and limited the possibilities of design in terms of both form and material, prompting designers to search for new processes. A new generation of making includes biomimicry-inspired technologies such as 3D printing and parametric simulation, which have transformed the production paradigm. Utilizing nature as industry, this thesis explores the possibility of “growing” designed objects by employing nature’s own processes and resources. It integrates bio materials, generative design and additive manufacturing to produce objects for a post-industrial world. The project outcomes employ natural minerals, crystallization and 3D printing to develop new forms of making, proposing a new suite of tools for designers.

Additive manufacturing has grown considerably during the last couple of decades, whether it comes to the printing of metal structure or living cells. Additive manufacturing techniques relays on the successive addition of material to create the wanted structure. Among the diversity of these many printing techniques, electrohydrodynamic 3D-printing is of particular interest, as the technique has a promising outlook for high-resolution printing on the microscale. The technique is compatible with a myriad of thermoplastics, but its writing resolution is limited due to the inherent affect the manufacturing process has on the material. Electrostatic forces between already deposited fibres and the fibre in light affect the final position of printed fibre. This thesis evaluates the possibility to increase the writing resolution in melt electrohydrodynamic 3D printing by a closed-loop feedback system. Components were built and added to an already existing printing setup to implement in-situ measurements of the fibres position as well as active electrostatic guiding of the fibre. The setup consisted of a camera that determined the position of the fibre; the position was then used in a PID controller to calculate an appropriate potential. The potential was forwarded to a high voltage amplifier, connected to a steering electrode, mounted in the vicinity of the jet. The setup built for one-dimensional steering of the fibre improved the printing accuracy by ten times through suppressing the repulsive/attractive forces, where the process variable of the PID controller was measured. However, the precision decreased roughly four times as it was deposited on the substrate. The limitations of the system have been evaluated, and possible improvements for the two-dimensional control of the fibre are further discussed.

Background: Additive manufacturing is a manufacturing process that has for the past 30 years been used substantially within the branch of industry. By adding material layer-by-layer, an object will be designed, and this method is called 3D-printing. Despite the advantage of building an object without assemblage as in traditional manufacturing, there is a lot of limitations with this additive manufacturing. Are there more opportunities than difficulties with additive manufacturing or is this manufacturing process too advanced too take over the traditional manufacturing process once and for all?    Purpose: The purpose with this study is to increase understanding for promises and challenges with additive manufacturing and in which context it is adequate to use. Which elements makes it more appropriate and which are less, with additive manufacturing.   Implementation: In the theoretical frame of reference, an integrative review study has been formed, by collecting and working with data from precious studies. The focus applies on the content of additive manufacturing, differences between traditional manufacturing and additive manufacturing only in theoretical frame of reference, promises and challenge with AM-processes, logistical aspects that focuses on the service elements that interact between organizations and customers but also the quality issues that concern additive manufacturing, order qualifiers and order winners that makes the establishment unique also adequacy of materials for different AM-processes. The empirics contain data and information from two concerned organizations that utilize additive manufacturing, but also how they go about to achieve competitive advantages. The analysis compiles the theoretical frame of reference that is formed by the data from previous additive manufacturing studies. Together with the empirics that has been brought by the concerned companies. Through the question formulation and a designed survey study that was given to the two companies, an information rich integrative review was embodied.   Conclusion: This case study shows, as well as other studies that concern additive manufacturing, the conclusion is the same. The conclusion shows that additive manufacturing leads to elements such as cost reduction regarding manufacturing, reduced tied capital, to shorten the lead time, less haul, more environmentally friendly and to make complex geometric objects that are hard to design through traditional manufacturing. There are differences between the companies chosen AM-processes, because each AM-process uses different material. Material offering is more considerable to Company A that uses plastics than to Rise Swecast AB that uses powder within metal production. Adequacy for additive manufacturing applies more to build geometric complex objects, manufacturing of lower production volumes. It applies less to larger production volumes, limit of material supplies of different AM-processes and also for building larger objects. There are also quality issues that concern the printout, thus there is no feedback equipment, but this controls after each printout to avoid variations between printouts and between AM-processes. Additive manufacturing will take more place in the industry branch, in the future, and eventually replace processes within the traditional production. There are great opportunities for additive manufacturing that will lead to profitability for companies and customers through decentralization, meaning that organizations do not need to invest in a whole factory. / Bakgrund: Additiv tillverkning är en tillverkningsprocess som har på de senare åren börjat användas avsevärt det senaste 30 åren, inom industribranschen. Genom att addera material lager-för-lager bildas ett objekt och denna metod kallas för 3D-printing. Trots fördelen med att kunna tillverka ett objekt komplett utan att behöva montera ihop delar som i traditionell tillverkning, finns det många begränsningar med additiv tillverkning. Finns det fler möjligheter än svårigheter med additiv tillverkning eller är tillverkningsprocessen för avancerat för att ta över den traditionella tillverkningsprocessen helt?   Syfte: Rapportens syfte är att öka förståelsen för möjligheter och svårigheter med additiva tillverkningsprocesser samt i vilken kontext det är lämpligt att använda. Vilka faktorer gör det mer eller mindre lämpligt med additiv tillverkning.   Genomförande: I studiens teoretiska referensram har en fallstudie utförts genom att samla in och bearbeta data från tidigare studier. Här utformas studiens teori med fokus på innebörden av additiv tillverkning, jämförelse mellan traditionell tillverkning samt additiv tillverkning enbart i TR, möjligheter och svårigheter med tillverkningsprocessen, logistiska aspekter som fokuserar på den leveransserviceelement som samspelas mellan företag och kunder samt att detta inkluderar kvalité problem som uppstår med AM, orderkvalificerare och ordervinnare som gör företagen unika samt lämplighet av material för olika additiva tillverkningsprocesser. I empirin hittas data och information från två berörda företag som använder sig av additiv tillverkning inom produktionsområden och hur de går tillväga för att uppnå konkurrensfördelar. I analysen sammanställs den teoretiska referensram som utformats med hjälp av data från tidigare studier om additiv tillverkning, tillsammans med empirin som tagits fram med hjälp av dessa två berörda företag. Genom ett frågeställningsformulär och en utformad enkätstudie som gavs till respektive företag, kunde en informationsrik litteraturstudie utföras.    Slutsats: Denna fallstudie visar likaså majoriteten av tidigare studier som berör additiv tillverkning, samma slutsats. Slutsatsen visar att additiv tillverkning leder till faktorer såsom kostnadsreducering gällande produktion, minskad bundet kapital, förkortade ledtider, färre transportsträckor, mer miljövänligt, skapa komplexa geometrier som är svårt att skapa på traditionellt vis. Det finns även skillnader mellan företagens valda AM-processer då företagen använder sig av olika tillverkningsprocesser och olika 3D-printer samt material. Materialutbudet är större hos Företag A som använder sig av plaster än hos Rise Swecast AB som använder sig av kvartssand vilket används inom metalltillverkning. Lämpligheten för additiv tillverkning passar mer vid uppbyggnad av komplexa geometrier, tillverkning av låga produktionsvolymer. Men lämpar sig mindre vid stora produktionsvolymer, begränsning vid materialval av olika AM-processer samt vid tillverkning av stora objekt. Det fanns även kvalitetsproblem gällande utskrifter då det inte finns några återkopplingsverktyg, men detta kontrolleras vid varje utskrift för att undvika variationer mellan utskrifter och processer. Additiv tillverkning kommer i framtiden att ta alltmer plats inom industribranschen och kommer även eventuellt att ersätta andra processer inom den traditionella tillverkningen just för att den bidrar med både med lönsamhet för företag samt kunder genom decentralisering, det vill säga att man inte behöver vara långt ifrån kunden samtidigt som man inte behöver investera i en hel fabrik.

The thesis aims to develop a prototype for a Smart Case for Remote Radio Kits at the department of Demo & Event at Ericsson in Kista.The smart case consists of a mechanical structure (the case itself with ) and an electronic system that includes a temperature sensor, a LCD display showing the temperature, a GPS (global positioning system) module for positioning the case, a GSM (Global System for Mobile Communications) module and a microcontroller Arduino UNO. The Case is modelled in 3D with the help of CAD software and then printed with a 3D printer. A down-scaled prototype is built with the help of the 3D printer and the 2D drawing will be used when the full scaled model is produced. The Arduino UNO handles temperature sensor and GPS measurements, LCD display, and the transmission of measurement data using GSM module via text message (SMS) to a cell phone or to a server over the Internet. The projected ended up with all the drawings and models finished for the Case as well as the implementation of down-scaled prototypes. The electrical system was tested and finished individually. But the complete system cannot be assembled inside the Case due to the time limitation. This means that the project can be further extended, where a full scale model can be developed and the electrical control system can be assembled together and mounted inside the Case.

Les substituts osseux synthétiques servent au remplacement temporaire des tissus osseux, favorisent la formation, la croissance et la survie de l’os et sont biorésorbables. Aucun matériau monophasé ne remplissant complètement ces exigences, un matériau composite bioinspiré est une alternative possible. L’objectif de cette thèse était par conséquent d’étudier la synthèse et les propriétés de deux composites biocéramiques/biopolymères : des hydrogels physiques de chitosane minéralisés avec de l’apatite, et une hardystonite architecturée imprégnée par des hydrogels physiques de chitosane. Afin d’obtenir le premier matériau, deux approches ont été développées. La première a consisté à fabriquer des hydrogels physiques de chitosane puis à les minéraliser avec de l’apatite ; la formation de microcapillaires se produit avec des conditions de synthèse spécifiques, et les précipités d’apatite ont été trouvés uniquement à la surface des hydrogels. La seconde approche consiste à convertir des suspensions homogènes contenant le phosphate de calcium et le chitosane en hydrogels de chitosane minéralisés par l’apatite. Les suspensions ont été préparées soit avec un mélange simultané, soit avec des mélanges successifs de suspensions phosphates de calcium avec les solutions de chitosane. Des agrégats minéraux plus petits avec une distribution plus uniforme ont été formés avec la méthode des mélanges successifs. Cela est attribué à une meilleure homogénéité, une viscosité plus faible et l’absence de chitosane. De manière générale, trois paramètres influencent les propriétés mécaniques d’hydrogels de chitosane minéralisés : la base utilisée pour la gélification (déterminant la vitesse de gélification : une grande vitesse conserve l’enchevêtrement des chaînes, résultant en une meilleure élasticité) ; la densité de la réticulation physique (cela induit un module de conservation plus important) et la force ionique (qui mène au désenchevêtrement des chaînes de chitosane, donc, à un faible module de conservation). Cette compréhension a permis l’utilisation de ces suspensions de phosphate de calcium-chitosane en tant qu’encre pour l’impression 3D. Les hydrogels de chitosane et les hydrogels minéralisés ne sont pas cytotoxiques. Pour fabriquer le second matériau, une encre pré-céramique a été imprimée en 3D puis frittée pour former une céramique d’hardystonite cristalline. Les scaffolds d’hardystonite ont été imprégnés par la solution de chitosane, converties ensuite en hydrogels physiques de chitosane. A plus forte concentration de chitosane, la viscosité de la solution était plus grande et l’imprégnation de la matrice plus lente. Avec une vitesse de gélification plus importante, qui dépend de la base utilisée pour la gélification, la perte de poids est plus faible pendant la gélification. L’hydrogel de chitosane a partiellement rempli les pores participant au support de charges externes et à la dissipation d’énergie par rupture. / Bone substitutes, an approach to attend social demand for bone healing and reparation, are temporary replacements of bone tissue, promote bone formation and growth and finally are bioresorbed. No single material meets these requirements; an alternative is a bioinspired composite material. The objective of this thesis was thus to study the synthesis and properties of two bioceramics/biopolymer composites: chitosan physical hydrogels mineralized with apatite and hardystonite scaffolds impregnated with chitosan physical hydrogels. To obtain the first material, two strategies were developed. The first one consisted in the fabrication of chitosan physical hydrogels and its subsequent mineralization with apatite; the formation of micro-capillaries occurred under particular synthesis conditions, and apatite precipitates were found only on the surface of hydrogels. The second strategy consisted in a simultaneous conversion of chitosan-calcium phosphate suspensions into chitosan-apatite hydrogels. The suspensions were prepared by sequential or simultaneous mixing of calcium and phosphate suspensions with chitosan solutions. Smaller and more uniformly distributed mineral aggregates were formed following sequential mixing, attributed to higher homogeneity, lower viscosity and no-presence of chitosan. This enabled the use of these chitosan-calcium phosphate suspensions as inks for 3-D printing. In general, three factors impacted the mechanical properties of mineralized chitosan hydrogels: the base used for gelation (determining the gelation rate: a higher rate preserved chain entanglement, resulting in higher elasticity); the density of physical crosslinks (hence a higher storage modulus) and the ionic strength (that led to chitosan chain disentanglements, thus, low storage modulus). Chitosan hydrogels and mineralized hydrogels were not cytotoxic, having no deleterious effects on osteoblasts proliferation. To fabricate the second material, pre-ceramic ink was 3-D printed and then sintered to form crystalline hardystonite ceramic. Hardystonite scaffolds were impregnated with chitosan solution that was, next, converted to chitosan physical hydrogel. At higher chitosan concentration, viscosity of solution was higher and scaffold impregnation was lower. At higher gelation rate, which depend on base used for gelation, lower weight loss during gelation. Chitosan hydrogel partially filled the pores contributing to bearing of external loads and to energy dissipated by fracture.

The following work explores the role of 3D printing in biological anthropology. A case study approach is used to provide an understanding of two different applications for 3D printing and to identify a potential methodology for creating 3D models. Case study one looks at the application of 3D printing to reconstruction projects using a flowerpot to test the reconstruction methodology. The second case study uses both laser surface and CT scanning to create a replica of a human skeleton. The two methods of data acquisition are evaluated for advantages and limitations in creating the virtual model. This work shows that there is a role for 3D printing in biological anthropology, but that data acquisition and processing issues are the most significant limiting factors in producing skeletal replicas. / October 2006

The miniaturization of projection technology has enabled a new class of lightweight mobile devices with embedded projectors. Projection engines as small as a postage stamp are currently being embedded in thousands of mobile devices. Mobile projector-based devices differ in very fundamental ways from the display-based devices we commonly use. Mobile projectors can be carried with the user and project imagery into almost any space, projected content is visible to multiple users and supports social interaction, physical objects and surfaces can be augmented with projected content, and embedded projectors can enable new form-factors for mobile displays. This research investigates the potential of mobile projectors as a new platform for human-computer interaction. I aim to demonstrate that the unique affordances created by the miniaturization of projection technology can inspire new and compelling interaction with single-users, multi-users, the environment, and projector-embedded objects. This research presents a comprehensive survey of mobile projector-based interaction – documenting interaction with historic projection devices; introducing novel interaction techniques, metaphors, and principles for mobile projector-based systems; providing implementation details of functional prototype devices using mobile projectors; presenting technical innovations, such as the development of specialized projectors and custom marker tracking algorithms; and detailing results from preliminary user testing with the prototype systems created. This research forms a systematic investigation of the past, the present, and a possible future for interaction using mobile projectors.

This thesis investigates inkjet printing of fully-integrated modules fabricated on organic substrates as a system-level solution for ultra-low-cost and eco-friendly mass production of wireless sensor modules. Prototypes are designed and implemented in both traditional FR-4 substrate and organic substrate. The prototype on organic substrate is referred to as a Smart Wireless Integrated Module (SWIM). Parallels are drawn between FR-4 manufacturing and inkjet printing technology, and recommendations are discussed to enable the potential of inkjet printing technology. Finally, this thesis presents novel applications of SWIM technology in the area of wearable and implantable electronics. Chapter 1 serves as an introduction to inkjet printing technology on organic substrates, wireless sensor networks (WSNs), and the requirements for low-power consumption, low-cost, and eco-friendly technology. Chapter 2 discusses the design of SWIM and its implementation using traditional manufacturing techniques on FR-4 substrate. Chapter 3 presents a benchmark prototype of SWIM on paper substrate. Challenges in the manufacturing process are addressed, and solutions are proposed which suggest future areas of research in inkjet printing technology. Chapter 4 presents novel applications of SWIM technology in the areas of implantable and wearable electronics. Chapter 5 concludes the thesis by discussing the importance of this work in creating a bridge between current inkjet printing technology and its future.

The following work explores the role of 3D printing in biological anthropology. A case study approach is used to provide an understanding of two different applications for 3D printing and to identify a potential methodology for creating 3D models. Case study one looks at the application of 3D printing to reconstruction projects using a flowerpot to test the reconstruction methodology. The second case study uses both laser surface and CT scanning to create a replica of a human skeleton. The two methods of data acquisition are evaluated for advantages and limitations in creating the virtual model. This work shows that there is a role for 3D printing in biological anthropology, but that data acquisition and processing issues are the most significant limiting factors in producing skeletal replicas.

Additive manufacturing (AM), also called 3D-printing, are technologies where parts are formed from the bottom up by adding material layer-by-layer on top of each other. Electron Beam Melting (EBM) is an AM technique capable of manufacturing fully solid metallic parts, using a high-intensity electron beam to melt powder particles in layers to form finished components. Compared to conventional machining, EBM offers enhanced efficiency for production of customized and patient specific parts such as e.g. dental prosthetics. However, dental prosthetics are challenging to produce by EBM, as their small sizes mean that mechanical and surface properties may be altered as part sizes decreases. The aim of this thesis is to gain new insights that could lead to optimization for production of small sized components in the EBM. The work is focused to understand the process-property relationships for small size components production. To improve the surface resolution and part detailing, a smaller sized powder was used for production and compared to parts made with standard sized powder. The surface-, chemical and mechanical properties were evaluated for parts produced with both types of powders. The results indicate that the surface roughness may be influenced by powder and build layer thickness size, whereas the mechanical properties showed no influence of the layer-wise production. However, the mechanical properties are dependent on part size. The outermost surface of the parts consists of a surface oxide dominated by TiO2, formed as a result of reaction between the surface and residual gases in the EBM build chamber. The surface oxide thickness is comparable to that of a conventionally machined surface, but is dependent on build height. This work concludes that the surface resolution and component detailing can be improved by various measures. Provided that proper process themes are used, the EBM manufactured material is homogenous with properties comparable to conventional produced titanium. It has also been shown that the material properties will be altered for small components. The results point towards different ways of optimizing manufacturing of dental prosthetics by EBM, which will make dental prosthetics available for an increased number of patients.