University of Pennsylvania Automated Design and Prototyping of Macro and Micro Compliant Mechanisms Compliant mechanism concept leads to a clean separation of design/modeling from manufacturing/assembly activities. The objective of this research is to provide a link between the two through efficient data translations and automated reverse engineering techniques. Optimal topology design of compliant mechanisms Automatic image interpretation and creation of solid model from optimized topology image Reverse engineering for microfabricated artifacts Image processing for edge-extraction and object-finding Writing IGES file for Pro-Engineer Macro prototyping using Stratasys FDM 1650 rapid prototyping system Micro prototyping using MCNC’s Multi-User-MEMS-Processes (MUMPs) Automated metrology for a ceramic meso-scale machining Objectives

University of Pennsylvania Performance Specifications Synthesis Solution Refined Design Solution Meshed Model for Analysis Solid Model from the Optimized Device Digital Format for SFF or CNC Mask Layout for Microfab. Micro Prototype Macro Prototype Refined Prototype CAD model from the macro prototype Design and Prototyping of Macro & Micro Compliant Mechanisms Fabrication/Prototyping Digital Interface Design Reverse Engineering Solid model from microscopic images

University of Pennsylvania

Image from the optical microscopeAfter edge extraction Edge Extraction from 2-D Images

University of Pennsylvania Image from the optical microscopeAfter edge extraction The lack of sharp edges corresponding to the actual structure poses a challenge in extracting the correct topology. Edge Extraction from 2-D Images

University of Pennsylvania Test image with sharp edges Extracted line segments ported into Pro-E in IGES format Test image with circular curves Extracted circular segments ported into Pro-E in IGES format Verification with Test Images

University of Pennsylvania Experimental Set-up for Optical Imaging

University of Pennsylvania From Fabricated MEMS Device to a Solid Model Optical microscope image of a compliant micro crimper After edge extraction 5 µm

University of Pennsylvania From Fabricated MEMS Device to a Solid Model (cont’d) IGES model exported into Pro-E with line and arc segments Extruded solid model ready for analysis

University of Pennsylvania From Fabricated MEMS Device to a Solid Model (cont’d) FDM prototype of compliant gripper Unloaded configurationDeformation under loading

University of Pennsylvania From Optimized Compliant Topology Image to a Solid Model Topology optimization does not give the shape precisely in both the “super structure” and “material density” approaches. Designer’s intuition is needed to interpret the image and to obtain a manufacturable form. Simple image processing is inadequate to capture the correct quantitative behavior of the optimized compliant topology. Use shape optimization to refine the topology image with stress and manufacturability constraints. Combine image processing with shape optimization to automate the entire process. Future Tasks

University of Pennsylvania From Optimized Compliant Topology Image to a Solid Model Optimized compliant topology using material density design parameterization IGES model with line and arc segments Image processing, edge extraction, and object finding

University of Pennsylvania From Optimized Compliant Topology Image to a Solid Model Solid model ready for rapid prototyping and/or detailed 3-D analysis Suitable flexibility is not obtained.