Influence of Tomographic Slice Thickness and Field of View Variation on the Reproduction of Thin Bone Structures for Rapid Prototyping Purposes-An in Vitro Study

This study assessed the influence of acquisition parameters of tomographic volumes on the reproduction of thin bone structures for rapid prototyping purposes. Two parameters were investigated: Field of View (FOV) and Slice Thickness (ST). The specimen was comprised of five pairs of 0.6 mm, 1.1 mm, 1.5 mm, 2.0 mm and 2.8 mm thick cortical bone plates. The plates were stuck into utility wax;the first plate of the pair was in vertical position while the second plate was oblique to the first one. Forty-five tomographic images were captured and separated into 3 groups of fifteen images. Each group had a specific FOV: 180 mm;250 mm and 430 mm, respectively. Within each of these three groups, tomographic slice thickness was varied for every five of the fifteen slices. Acquisitions were carried out with STs of 1 mm, 2.5 mm and 5 mm. The Cyclops Medical Station software was used in the voxel-to-voxel analysis of radiologic density, reaching a total of 1350 assessed images. ST and FOV variation influenced the reproduction of thin bone walls, and FOV was shown to be a very important parameter. The larger the acquisition FOV, the more reduction in the number of voxels within the range of reconstruction for cortical bone in all of the bone plates. The visual analysis of the images of very thin bone walls showed that there could be a sharp drop in the radiologic density value in several adjacent voxels, resulting in areas which might not be reproduced in the reconstruction.

Research on Nanofabrication Technology of Micro-/Nano-Stereo Rapid Prototyping of PCVD

At present, the most common micro/nano-scale fabri ca tion processes include the plane silicon process based on IC technology, stereo silicon process, LIGA, quasi-LIGA based on near ultra violet deep lithography, MEMS, energy beam etching and micro/nano-machining, etc. A common problem for t hese processes is the difficulty to fabricate arbitrary form for 3-dimensional micro/nano-parts, devices or mechanisms. To develop advanced MEMS manufacturin g technology, and to achieve fabrication of true 3-dimensional parts, devices or mechanisms, this paper proposes a nanofabrication technology for rapid proto typing of 3-dimensional parts, using plasma chemical vapor deposition (PCVD). This process can be describes as follows: A laser beam is produced by a low power, quasi molecule laser. It enters the vac uum chamber through a window, and is focused on with the substrate surface. A ga s in the chamber is ionized by the laser beam to produce PCVD on the substrate s urface, and forms a particle of the size of Ф100 nm (its thickness is about 100 nm). When the laser beam moves along X-axis, many particles form a line. Then the laser beam moves one step in Y-axis to form a new line. A plane is complete d by many lines. Then the substrate moves in Z-axis to form new plane. Eventu ally, many planes form a 3-dimensional component. Using available CAD/CAM softw are with this process, rapid prototyping of complex components can be achieved. A nanometer precision linear motor, such as that described in Chinese national p atent (patent No. ZL 98 2 16753.9), can be used to obtain the nanometer precisio n movements in the process. The process does not require mask, can be used for v arious rapid prototyping materials, to obtain high fabrication precision (its sc ale precision is 15 nm), and larger ratio of height to width of micro/nano-stru cture. It can find widespread applications in the fabrication of micro-mechani sm, trimming IC, and fabricating minilens, etc.

Conversion of Rapid Prototyping Models into Metallic Tools by Ceramic Moulding—an Indirect Rapid Tooling Process

A process to convert models made by rapid prototypi ng techniques like SL (stereolitography) and LOM (laminated object manufacturing) or by conventional techniques (silicones, resins, wax, etc.) into metallic mould s or tools has been developed. The main purpose of this technique is to rapidly obtain the first prototypes of parts, for plastics injection, forging or any oth er manufacturing process using the tools produced by casting a metal into a cera mic mould. Briefly, it can be said that the ceramic moulds are produced by mixing in variab le proportions, depending on the type of ceramics employed, strength and roughne ss desired, a ceramic mixture composed by alumina and/or zirconium silicates bon ded with silica coming from a liquid binder, based on ethyl silicate. A catalyst is added to the slurry in order to produce a sol-gel reaction. The liquid slur ry is poured into the box containing the mould to be reproduced. After a short p eriod of time, controlled by the amount of gelling agent, the ceramic mixture ac quires a rubber consistency. The pattern is removed from the ceramic mould, whic h is fired to stop the gelation reaction. After this stabilization the ceramic m ould is sintered at high temperatures in order to generate an inert mould wi th the desired strength in which almost all metallic alloys can be cast. The effect of ceramic materials (shape, granulometric distribution, chemical com position, etc.), processing parameters (proportion binder/ceramic/catalyst, sint ering conditions, etc.) and casting conditions (mould pre-heating temperature a nd pouring temperature) were studied in order to obtain metallic moulds or tools with tailored properties (high dimensional accuracy, low roughness and high mec hanical strength).

Accuracy of Rapid Prototyping Biomodels Plotted by Three Dimensional Printing Technique:Ex Vivo Study

The rapid prototyping biomodels manufacturing is a recent technology with great importance in oral and maxillofacial surgery. It provides a better surgical planning, decrease of anesthesia time and great functional and esthetic results. The aim of this experimental study was to evaluate the accuracy of rapid prototyping biomodels built by three-dimensional printing (3DP) technique, since this is one of the least expensive methods available. Linear measurements of standardized bone defects and anatomic distances were compared using a digital caliper of high precision in nine dry mandibles (gold standard) and their respective biomodels. The Bland-Altman test was used for statistical analysis (5% level of significance). The results showed strong concordance between the dry mandibles and their respective biomodels, with discrepancies smaller than 2 mmin most cases (97.4%). We can conclude that the biomodels built by 3DP technique can be used for surgical planning in Dentistry.

Rapid Prototype Development Approach for Genetic Programming

Genetic Programming (GP) is an important approach to deal with complex problem analysis and modeling, and has been applied in a wide range of areas. The development of GP involves various aspects, including design of genetic operators, evolutionary controls and implementations of heuristic strategy, evaluations and other mechanisms. When designing genetic operators, it is necessary to consider the possible limitations of encoding methods of individuals. And when selecting evolutionary control strategies, it is also necessary to balance search efficiency and diversity based on representation characteristics as well as the problem itself. More importantly, all of these matters, among others, have to be implemented through tedious coding work. Therefore, GP development is both complex and time-consuming. To overcome some of these difficulties that hinder the enhancement of GP development efficiency, we explore the feasibility of mutual assistance among GP variants, and then propose a rapid GP prototyping development method based on πGrammatical Evolution (πGE). It is demonstrated through regression analysis experiments that not only is this method beneficial for the GP developers to get rid of some tedious implementations, but also enables them to concentrate on the essence of the referred problem, such as individual representation, decoding means and evaluation. Additionally, it provides new insights into the roles of individual delineations in phenotypes and semantic research of individuals.

Photolithography-free fabrication of photoresist-mold for rapid prototyping of microfluidic PDMS devices

Traditional soft lithography based PDMS device fabrication requires complex procedures carried out in a clean room. Herein, we report a photolithography-free method that rapidly produces PDMS devices in 30 min. By using a laser cutter to ablate a tape, a male photoresist mold can be obtained within 5 min by a simple heating-step, which offers significant superiority over currently used photolithographybased method. Since it requires minimal energy to cut the tape, our fabrication strategy shows good resolution(~ 100 μm) and high throughput. Furthermore, the micro-mold height can be easily controlled by changing the tape types and layers. As a proof-of-concept, we demonstrated that the fabricated PDMS devices are compatible with biochemical reactions such as quenching reaction of KI to fluorescein and cell culture/staining. Collectively, our strategy shows advantages of low input, simple operation procedure and short fabrication time, therefore we believe this photolithography-free method could serve as a promising way for rapid prototyping of PDMS devices and be widely used in general biochemical laboratories.

Material solidity in rapid prototyping

There are four key technologies in rapid prototyping: rapid solidified photo-cured material, stable and continuous ultraviolet laser with small spot, precise 3D stage, and flexible CAD software. The photo-cured polymer plays an important role in rapid prototyping,for which not only rapid solidification, but also the high strength, small deformation and stress, one-time high solidity and fixed lamination are needed. In addition, product hardness or softness is relative to the material solidity. So the controlling to the material solidity is a key problem in rapid prototyping.

Study on Control of Pneumatic Selecting and Shifting Actuators Using Rapid Control Prototyping

A gearbox in-the-loop control platform using dSPACE real-time system is designed for the study on the control technology of pneumatic selecting and shifting actuators based on rapid control prototyping.The operational principle of such actuators was analyzed using dSPACE hardware and software,resulting in a better knowledge of the logical relationship among solenoid valves,gear positions of cylinders and system input/output.Based on these,a control model was developed under the Matlab/Simulink environment and rapidly improved to meet requirements through experiments.Relevant tests have shown that analysis efficiency on selecting and shifting actuators could be raised and development of control strategy facilitated.

An Integrated Control Framework for Torque Vectoring and Active Suspension System

Four-wheel independently driven electric vehicles(FWID-EV)endow a flexible and scalable control framework to improve vehicle performance.This paper integrates the torque vectoring and active suspension system(ASS)to enhance the vehicle’s longitudinal and vertical motion control performance.While the nonlinear characteristic of the tire model leads to a relatively heavier computational burden.To facilitate the controller design and ease the load,a half-vehicle dynamics system is built and simplified to the linear-time-varying(LTV)model.Then a model predictive controller is developed by formulating the objective function by comprehensively considering the safety,energy-saving and comfort requirements.The in-wheel motor efficiency and the power loss of tire slip are treated as optimization indices in this work to reduce energy consumption.Finally,the effectiveness of the proposed controller is verified through the rapid-control-prototype(RCP)test.The results demonstrate the enhancement of the energy-saving as well as comfort on the basis of vehicle stability.

Prototyping: Major Advance in Surgical Planning and Customizing Prostheses in Patients with Bone Tumors of the Head and Neck

Major resections of bone tumors of the head and neck, owing to their small dimensions and their proximity to the organs in this region, cause important functional and aesthetic problems that significantly compromise patients’ quality of life. Therefore, therapeutic planning should always extend beyond the resection to include functional and aesthetic reconstruction, preferably immediately. Microsurgical reconstruction represents a significant advance, but has not yet been perfected. Rapid prototyping (RP) comes as a new technology for the purpose of assisting the surgeon in the visual and tactile aspects of surgery, providing diagnostic accuracy and increasing the success of surgical planning. The authors demonstrate the technological advances in the manufacture of customized mandibular prostheses with the assistance of RP and practical applications of these methods.

Investigating on casting mold (or core) making with coated sand by the selected laser sintering

Using a special coated sand as the material of the selected laser sintering (SLS), the authors test and investigate the strength change of the test samples in terms of different sintering parameters (scanning speed, laser power, sintering thickness, and so on). The characteristics of coated sand hardening by laser beam are analyzed. The sintered mold (or core) for given casting is poured with molten metal.

A review of additive manufacturing technology and its application to foundry in China

The application of additive manufacturing technology is one of the main approaches to achieving the rapid casting.Additive manufacturing technology can directly prepare casting molds(cores)with no need of patterns,and quickly cast complex castings.The combination of additive manufacturing and traditional casting technology can break the constraint of traditional casting technology,improve casting flexibility,and ameliorate the working environment.Besides,additive manufacturing promotes the realization of"free casting",greatly simplifying the processing procedures and shortening the manufacturing cycle.This paper summarizes the basic principle of additive manufacturing technology and its development situation domestically and overseas,mainly focusing on the development status of several main additive manufacturing technologies applicable to the foundry field,including three-dimensional printing,selective laser sintering,stereolithography,layered extrusion forming,etc.Finally,the future development trend of additive manufacturing technology in the foundry field is prospected.

Localized electrodeposition micro additive manufacturing of pure copper microstructures

The fabrication of pure copper microstructures with submicron resolution has found a host of applications,such as 5G communications and highly sensitive detection.The tiny and complex features of these structures can enhance device performance during high-frequency operation.However,manufacturing pure copper microstructures remain challenging.In this paper,we present localized electrochemical deposition micro additive manufacturing(LECD-μAM).This method combines localized electrochemical deposition(LECD)and closed-loop control of atomic force servo technology,which can effectively print helical springs and hollow tubes.We further demonstrate an overall model based on pulsed microfluidics from a hollow cantilever LECD process and closed-loop control of an atomic force servo.The printing state of the micro-helical springs can be assessed by simultaneously detecting the Z-axis displacement and the deflection of the atomic force probe cantilever.The results showed that it took 361 s to print a helical spring with a wire length of 320.11μm at a deposition rate of 0.887μm s^(-1),which can be changed on the fly by simply tuning the extrusion pressure and the applied voltage.Moreover,the in situ nanoindenter was used to measure the compressive mechanical properties of the helical spring.The shear modulus of the helical spring material was about 60.8 GPa,much higher than that of bulk copper(~44.2 GPa).Additionally,the microscopic morphology and chemical composition of the spring were characterized.These results delineate a new way of fabricating terahertz transmitter components and micro-helical antennas with LECD-μAM technology.

On Application of Metal Additive Manufacturing

Metal additive manufacturing is an important branch of AM, which provides an effective method for the innovative manufacturing of metal parts. Here, flow chart and main techniques of metal additive manufacturing are firstly described according to the used material types. Many application examples of metal additive manufacturing are then listed based on application value. The summary is finally given to point development direction of metal additive manufacturing in the future. Additive manufacturing, which is an effective supplement to traditional methods, will play an important role in intelligent and digital manufacturing.

Investigation on preheating process in SLS machine

Selective laser sintering (SLS) is an important Rapid Prototyping method because its wide range of materials. The powder is fused and processed into a part because it is heated in the process. Preheating of powder on the surface of powder bed is a one important process which is a guarantee by which parts can be successfully fabricated and influences accuracy of parts fabricated in SLS technology. The uniformity of temperature on powder bed influences accuracy and performance of parts. It is necessary to understand the influences of the parameters of preheating set on uniformity of temperature on surface of powder bed. This paper analyzes general preheating process of irradiator for the preheating of powder on the surface of powder bed during SLS processing, and investigates influences of the flux density on the temperature field on the top surface of powder bed. The models of distribution of flux density and the distribution of surface temperature of powder bed are presented. The result predicted according to the models is reasonably consistent with experimental result. This model plays important role in design of preheating set and control of SLS processing. It is concluded that the uniformity of temperature field on the powder bed is determined mostly by the geometry of heating component and its fix location and the flux density is inverse proportional to the highness.

Development of a Wireless Environmental Data Acquisition Prototype Adopting Agile Practices: An Experience Report

The traditional software development model commonly named “waterfall” is unable to cope with the increasing functionality and complexity of modern embedded systems. In addition, it is unable to support the ability for businesses to quickly respond to new market opportunities due to changing requirements. As a response, the software development community developed the Agile Methodologies (e.g., extreme Programming, Scrum) which were also adopted by the Embedded System community. However, failures and bad experiences in applying Agile Methodologies to the development of embedded systems have not been reported in the literature. Therefore, this paper contributes a detailed account of our first-time experiences adopting an agile approach in the prototype development of a wireless environment data acquisition system in an academic environment. We successfully applied a subset of the extreme Programming (XP) methodology to our software development using the Python programming language, an experience that demonstrated its benefits in shaping the design of the software and also increasing productivity. We used an incremental development approach for the hardware components and adopted a “cumulative testing” approach. For the overall development process management, however, we concluded that the Promise/Commitment-Based Project Management (PB-PM/CBPM) was better suited. We discovered that software and hardware components of embedded systems are best developed in parallel or near-parallel. We learned that software components that pass automated tests may not survive in the tests against the hardware. Throughout this rapid prototyping effort, factors like team size and our availability as graduate students were major obstacles to fully apply the XP methodology.

Advanced Additive Remanufacturing Technology

Additive remanufacturing technology,as one of the key technologies of remanufacturing engineering,can realize the integrated repair of the structure and function of high value-added key metal parts of large and complex equipment,which can significantly reduce the use and maintenance costs,save labor and time costs.It applies to the on-site repair and remanufacturing of key parts in the aerospace,energy and chemical industry,heavy haul machinery,and other fields,as well as the on-site rapid repair of parts in special environments such as tunnels,open seas,and space.Additive remanufacturing technology can promote the reform of the maintenance and support mode of weapons and equipment and become the research hotspot of major military-developed countries.This paper expounds on the connotation and characteristics of additive remanufacturing technology and introduces its evolution process.The research achievements of the author in the development of additive remanufacturing platforms,material design,and process optimization were summarized.Given the problems(such as control shape,control performance,and control position)in the additive remanufacturing process,the author puts forward solutions and looks forward to the future development direction of additive remanufacturing technology.

Analysis on fused deposition modelling performance

Fused deposition modelling (FDM) is one of rapid prototyping (RP) technologies which uses an additive fabrication approach.Each commercially available FDM model has different types of process parameters for different applications.Some of the desired parts require excellent surface finish as well as good tolerance.The most common parameters requiring setup are the raster angle,tool path,slice thickness,build orientation,and deposition speed.The purpose of this paper is to discuss the process parameters of FDM Prodigy Plus (Stratasys,Inc.,Eden Prairie,MN,USA).Various selected parameters were tested and the optimum condition was proposed.The quality of the parts produced was accessed in terms of dimensional accuracy and surface finish.The optimum parameters obtained were then applied in the fabrication of the master pattern prior to silicone rubber moulding (SRM).These parameters would reduce the post processing time.The dimensional accuracy and surface roughness were analyzed using coordinate measuring machine (CMM) and surface roughness tester,respectively.Based on this study,the recommended parameters will improve the quality of the FDM parts produced in terms of dimensional accuracy and surface roughness for the application of SRM.

Digital/Analog Simulation Platform for Distributed Power Flow Controller Based on ADPSS and dSPACE

Distributed power flow controller,which is among the most powerful distributed flexible transmission equipments,is still only in the stage of the oretical research and digital simulation.In order to promote the engineering demonstration of a distributed power flow controller,it is urgent to establish a digital/analog simulation platform that supports closed-loop real-time simulation of a distributed power flow controller.In this paper,the electromagnetic transient model of a distributed power flow controller is established on ADPSS(advanced digital power system simulator).The rapid control prototype realized by dSPACE is connected to ADPSS to form a digital/analog simulation platform for a distributed power flow controller.Through a voltage control and power flow control simulation of the test system with a distributed power flow controller,the correctness and effectiveness of the constructed simulation platform are verified,which provides a new way for the verification of the new theory of a distributed power flow controller.