Digital light Projection based Additive Manufacturing (AM) enables fabrication of complex three-dimensional (3D) geometries for applications ranging from rapid prototyping jet parts to scaffolds for cell cultures. Despite the ability in producing complex, three-dimensional architectures, the state of art DLP AM systems is limited to a single homogenous photo-polymer and it requires a large volume of resin bath to begin with. Extensible Multi-material Stereolithography (EMSL) is a novel high-resolution projection stereolithography system capable of manufacturing hybrid 3D objects. This system provides new capabilities, allowing more flexible design criteria through the incorporation of multiple feedstock materials throughout the structure. With EMSL manufacturing ability, multi-material programmable negative Poissons ratio honeycomb reentrant structures are realized.
Researchers have been studying auxetic structures over decades, the mechanical property control of auxetic structure mainly relies on geometry design in previous studies. Now with the help of EMSL system, other design variables associated with auxetic structures, such as material properties of local structural members, are added into design process. The additional variables are then proved to have significant effects on the material properties of the auxetic structures. The ability to accurately manufacture multi-material digital design will not only allow for novel mechanical and material researches in laboratory, but also extend the additive manufacturing technology to numerous future applications with characteristics such as multiple electrical, electromechanical and biological properties. The design and optimization of EMSL system realizes novel structures have not been producible, therefore it will stimulate new possibilities for future additive manufacturing development. / Master of Science / Since 1970s, stereolithography, one of the most commonly known additive manufacturing techniques nowadays, has been improving the ability we make things. Through the controllable and repeatable photo-polymerization process, stereolithography can manufacture three-dimensional (3D) physical objects with fast speed, high accuracy and highly detailed surface finish. Today, stereolithography is already widely used in various rapid prototyping and manufacturing areas including dental products, jewelry prototypes, structural and tooling components. While latest researches continuously push its resolution to smaller scale or wider areas, this process is still limited to single material manufacturing.
To go beyond this manufacturing limitation, this thesis reports an Extensible Multimaterial Stereolithography (EMSL) system. This system takes advantages of the sequential projections from a digital light modulator, combined with several lowcost while efficient mechatronics components to enable printing at least two types of materials with distinct colors or mechanical properties. With the multi-material printing capability from EMSL, novel multi-material 3D auxetic structures, which have only been theoretical concepts, are successfully manufactured and tested. The reliability of EMSL process and properties of the new materials are investigated with experiments and numerical calculations. The system can be further extended to print multiple feedstock materials into one complex architectural assembly.
By realizing multi-material manufacturing capability, EMSL has broaden the potential applications of additive manufacturing and it will enable the development of multiple research and application areas including metamaterial, micro-electromechanical systems and bio-medical implants.
| Identifer | oai:union.ndltd.org:VTETD/oai:vtechworks.lib.vt.edu:10919/74961 |
| Date | 07 February 2017 |
| Creators | Chen, Da |
| Contributors | Mechanical Engineering, Zheng, Xiaoyu, Wicks, Alfred L., Kong, Zhenyu |
| Publisher | Virginia Tech |
| Source Sets | Virginia Tech Theses and Dissertation |
| Detected Language | English |
| Type | Thesis |
| Format | ETD, application/pdf |
| Rights | In Copyright, http://rightsstatements.org/vocab/InC/1.0/ |
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