Lamina emergent mechanisms (LEMs) are a subset of compliant mechanisms which are fabricated from planar materials; use compliance, or flexibility of the material, to transfer energy; and have motion that emerges out of the fabrication plane. LEMs provide potential design advantages by reducing the number of parts, reducing cost, reducing weight, improving recyclability, increasing precision, and eliminating assembly, to name a few. However, there are inherent design and modeling challenges including complexities in large, non-linear deflections, singularities that exist when leaving the planar state, and the coupling of material properties and geometry in predicting mechanism behavior. This thesis examines the planar and spherical LEMs and their relation to origami. Origami, the art of paper folding, is used to better understand spherical LEMs and flat-folding mechanisms in general. All single-layer planar four-bar LEMs are given with their respective layouts. These are all change-point pinned mechanisms (i.e. no slider cranks). Graph representations are used to show the similarities between action origami and mechanisms. Origami principles of flat-folding are shown to be analogous to principles of mechanisms including rules for assembly and motion.

There is an increasing need for compact mechanical systems that can accomplish sophisticated tasks. Technologies like ortho-planar and lamina emergent mechanisms (LEMs) have been developed to satisfy needs like these by stowing in planar sheets from which they emerge to perform their function. They can be compact, lightweight, monolithic, scalable, and can withstand harsh environments. They are limited, however, by their base element---planar surfaces. Applications requiring these advantages often include curved surfaces, like aircraft wings, needles, and automotive bodies. In this research, developable mechanisms are presented as a solution to satisfy the need for mechanisms that can conform to or emerge from curved surfaces. Foundational principles which enable designers to leverage the advantages of developable mechanisms are described herein.Developable mechanisms result from the union of mechanisms and developable surfaces. Developable (flattenable) surfaces act as a fitting medium because of their particular advantages in manufacturability and how well they accompany four-link, revolute joint (4R) mechanisms. The definition, including specific qualifying criteria, for developable mechanisms is given. Certain types of mechanisms and classes of developable surfaces can be combined to satisy that criteria. Developable mechanism sub-classes are defined as planar, cylindrical, conical and tangent developable mechanisms. It is shown that planar and spherical mechanisms can be used to create cylindrical and conical developable mechanisms, respectively. The Bennett and other 7R mechanisms can be used for tangent developable mechanisms. Steps for developable mechanism creation are presented, and several physical prototypes are provided to demonstrate feasibility.The cylindrically curved Lamina Emergent Torsional (LET) joint is offered as an enabling technology for producing compliant developable mechanisms. A mathematical model predicting force-deflection and stress behavior is provided and verified. The relationship between stiffness and strain energy storage for curved sheet materials with incorporated LET joints is explored. Material shape factors are used to derive an effective modulus of elasticity and an effective modulus of resilience, which are compared with original values on an Ashby plot. While there is a decrease in the modulus of resilience, there is a much more significant decrease in the modulus of elasticity. A material performance index is provided as an example for determining suitable materials for a given stiffness-reduction application. It is shown that the cylindrically curved LET joint makes it possible to create highly flexible joints that maintain much of their energy storage capability in curved sheet materials.

This thesis introduces lamina emergent mechanisms (LEMs) and presents components that can be used as building blocks to create LEMs capable of more complex motion. As the name suggests, lamina emergent mechanisms are fabricated out of planar materials (the lamina) but their motion is out of that plane (emergent). Lamina emergent mechanisms can provide benefits that include reduced manufacturing costs and minimal volume when in the planar state. The compact initial state of LEMs is beneficial in reducing shipping costs, especially in volume critical applications. LEMs also exhibit the potential benefits of compliant mechanisms, namely increased precision, reduced weight, reduced wear, and part count reduction. The LEM components presented in this thesis include flexible segments, fundamental mechanisms, and a new complaint joint, the lamina emergent torsional (LET) Joint. The flexible segments are developed through changes in geometry, boundary/loading conditions, and material. The fundamental mechanisms presented have motion similar to planar change-point four-bar and six-bar mechanisms, and spherical change-point mechanisms. The LET Joint is presented as a compliant joint suited for applications where large angular rotation is desired, but high off-axis stiffness is not as critical. The joint is introduced and the equations necessary for determining the force-deflection characteristics and stress are presented. Since the LET Joint can be fabricated from a single planar layer, it is well suited for macro and micro applications. Illustrative examples of the LET Joint are provided with devices fabricated from materials as diverse as steel, polypropylene, and polycrystalline silicon.

A deeper understanding of human development and disease is made possible partly through the study of genetically modified model organisms, such as the common mouse (Mus musculus). By genetically modifying such model organisms, scientists can activate, deactivate, or highlight particular characteristics. A genetically modified animal is generated by adding exogenous (foreign) genetic material to one or more embryonic cells at their earliest stages of development. Frequently, this exogenous genetic material consists of specially engineered DNA, which is introduced into a fertilized egg cell (zygote). When successfully introduced into the zygote, the exogenous DNA will be incorporated into the cell's own genome, and the animal that develops from the zygote will exhibit the genetic modification in all of its cells. The current devices and methods for generating genetically modified animals are inefficient, and/or difficult to use. The most common and efficient method for inserting new DNA into zygotes is by directly injecting a DNA solution through a tiny glass tube into the cell in a process called microinjection. Unfortunately, microinjection is quite inefficient (success rates are commonly between 1 and 5%), but often it is the only method for inserting DNA into eggs, zygotes, or early stage embryos. This thesis presents the design and testing of a micrometer sale, pumpless microelectromechanical system (MEMS) nanoinjector. Rather than use pumps and capillaries, the nanoinjector employs electrostatic charges to attract and repel DNA onto and off of the surface of a solid lance. The nanoinjector also includes a mechanical system for constraining the target cells during injection. Initial testing indicates the nanoinjector does not decrease cell viability, and it has a very high initial success rate (up to 90%). With the addition of an on-chip actuator, the nanoinjector could be packaged as an inexpensive, fully automated system, enabling efficient, high volume genetic modification of developing animals. Such a device would greatly increase the ease and speed of generating the model organisms needed to study such critical diseases such as Alzheimer's disease, cancer, and diabetes.

Limited resources are currently available to assist engineers in implementing compliant members into mechanical designs. As a result, engineers often have little to no direction incorporating compliant mechanisms. This thesis develops a conceptual design framework and process that utilizes a proposed classification scheme and a library of mechanisms to help engineers incorporate compliant mechanisms into their applications. As the knowledge related to the synthesis and analysis of compliant mechanisms continues to grow and mature, and through the classification scheme established in this thesis, compliant mechanisms may become more extensively used in commercial mechanical designs. This thesis also demonstrates a design approach engineers can use to convert an existing rigid-body mechanism into a compliant mechanism by using the established classification scheme and a library of compliant mechanisms. This approach proposes two possible techniques that use rigid-body replacement synthesis in conjunction with a compliant mechanism classification scheme. One technique replaces rigid-body elements with a respective compliant element. The other technique replaces a complex rigid-body mechanism by decomposing the mechanism into simpler functions and then replacing a respective rigid-body mechanism with a compliant mechanism that has a similar functionality. These techniques are then demonstrated by developing and designing a competitive and feasible compliant road bicycle brake system.

Lamina emergent mechanisms (LEMs) can provide a way to meet the demand for more compact and inexpensive mechanisms. Previous research has developed LEM designs and identified applications for them, but many applications would benefit from suitable actuation techniques. This thesis presents the design considerations and a variety of applicable methods for internal and external LEM actuation in the macro scale. Integrated LEM actuator possibilities have been identified, each with its advantages and disadvantages depending on the application. Shape memory alloys are especially compatible with LEMs. Traditional actuators have also been discussed as a way of actuating a LEM from the outside for cases in which space constraints allow it. The feasibility of new internal actuators using basic actuation principles, especially flat solenoids, has been explored. The magnetic field distribution along the axis of a high-aspect-ratio solenoid has been derived. Analytical and experimental results show that the output force of a high-aspect-ratio solenoid is suitable for LEMs. A pseudo-solenoid conceptual prototype was manufactured and evaluated, revealing challenges for which solutions have been recommended.

Origami-inspired design is an emerging field capable of producing compact and efficient designs. The object of a surrogate fold is to provide a fold-like motion in a non-paper material without undergoing yielding. Compliant mechanisms provide a means to achieve these objectives as large deflections are achieved. The purpose of this thesis is to present a summary of existing compliant joints suitable for use as surrogate folds. In doing so, motions are characterized which no existing compliant joint provides. A series of compliant joints is proposed which provides many of these motions. The possibility of patterning compliant joints to form an array is discussed. Arrays capable of producing interesting motions are noted.

Multiple-layer Lamina Emergent Mechanisms (MLEMs) are mechanisms made from multiple sheets (lamina) of material with motion that emerges out of the fabrication plane. This study has shown that understanding how layers are used in existing products and in nature provides insight into how MLEMs can also use layers to achieve certain tasks. The multi-layered nature of MLEMs and the interactions between these layers are what enhance the capabilities of MLEMs and allow them to better meet design objectives. Layer separation is one objective for which MLEMs are well-suited. Layer separation can have a variety of applications and there are a number of different ways to design a MLEM to achieve this objective. Single-layer LEM and MLEM designs could greatly benefit from suitable actuation techniques; those that are consistent with the advantages of these mechanisms and could be incorporated into their design. This work presents shape memory alloys, piezoelectrics and dielectric elastomers as suitable ways of actuating LEMs and MLEMs. A number of novel MLEMs are presented throughout this thesis.

Lamina emergent mechanisms (LEMs) are a maturing technology that is prepared for commercial implementation into new products. LEMs are defined by three functional characteristics; they (1) are compliant, (2) are fabricated from planar materials, and (3) emerge from a flat initial state. Advantages, design challenges, and design tools are described for each of the functional characteristics. Opportunities for LEMs are discussed, namely disposable LEMs, novel arrays of LEMs, scaled LEMs, LEMs with surprising motion, shock absorbing LEMs, and deployable LEMs. Technology push product development processes were employed to select applications for LEMs. LEM technology was characterized. In a LEM workshop, eighteen industry professionals then helped identify over 200 potential applications for the technology. The applications were evaluated, and the most promising ideas that were identified for each LEM opportunity are described with graphics of possible product embodiments. Of the various product opportunities enabled by LEMs, deployable mechanisms – particularly in the credit card size – are among the most viable. The compactness and portability of credit-card-sized products create a strong motivation for their development. Expanding the capabilities of credit-card-sized mechanisms to include more sophisticated motions and a broader range of tasks may dramatically increase their market potential. A review of the current state-of-the-art in credit-card-sized mechanisms reveals two primary classes of mechanisms most commonly used in this form factor: rigid-body mechanisms and in-plane compliant mechanisms. The limitations of each and corresponding LEM advantages are described. Criteria for determining whether a product is a suitable candidate for using LEM technology to create or improve a credit-card-sized product are established. The advantages of LEMs in credit-card-sized products are illustrated through an example product: a compact lancing device that could be used as a main component for a highly portable epinephrine syringe.

This work explores the use of carbon-infiltrated carbon nanotube (CI-CNT) forests as a material for fabricating compliant MEMS devices. The impacts of iron catalyst layer thickness and carbon infiltration time are examined. An iron layer of 7nm or 10nm with an infiltration time of 30 minutes produces CI-CNT best suited for compliant applications. Average maximum strains of 2% and 2.48% were observed for these parameters. The corresponding elastic moduli were 5.4 GPa and 4.1 GPa, respectively. A direct comparison of similar geometry suggested CI-CNT is 80% more flexible than single-crystal silicon. A torsional testing procedure provided an initial shear modulus of about 5 GPa for the 7-nm, 30-min CI-CNT. The strain and elastic modulus values were used to design numerous functional devices which were then fabricated in CI-CNT. A series of compliant cell restraint mechanisms were developed, assessed, and revised. A passive restraint with no moving parts was found to be both the most effective design and the easiest design to produce economically. A refined version of the passive restraint has been released commercially. Another series of designed devices successfully demonstrates the implementation of CI-CNT LEM designs.