Collaborative Research: A Novel Control Strategy for 3D Printing of Micro-Scale Devices

协作研究：微型设备 3D 打印的新型控制策略

• 批准号: 1737688
• 负责人: David Hoelzle
• 金额: $ 5.52万
• 依托单位: Ohio State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2016
• 资助国家: 美国
• 起止时间: 2016-09-01 至 2017-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1737688&HistoricalAwards=false
• 关键词: Collaborative; Research; Novel; Control; Strategy

Additive manufacturing systems, often called 3D printers, are poised to displace conventional manufacturing operations in many meso-scale applications (parts from 1 to 100 millimeters in size). Similarly, 3D printing at the micro-scale (from 0.001 to 0.1 millimeters in size) has the potential to revolutionize the way that biological and chemical sensors and integrated circuits are prototyped and manufactured. 3D printers build up complex parts by depositing one thin layer of material at a time. Electrohydrodynamic jet, or e-jet, printing is a promising micro-scale version of this process. This project will add sensors to a standard e-jet printer, and apply an innovative control law to greatly improve the precision of the resulting parts. The control law is based on the observation that 3D printed features typically change very little from one layer to the next. By observing how a layer deviates from its desired shape, the baseline e-jet control can be modified to improve the accuracy of the next layer. In this project, an atomic force microscope will be integrated with an e-jet printer to measure the shape of each layer. To better correct the printing process, the electric field around each layer will also be measured. The technical research plan is integrated with educational outreach to initiate undergraduate "micro-maker" clubs and catalyze an open-source, bottom-up movement based on inexpensive ink-jet printing of custom microcircuits and sensors.Micro-scale Additive Manufacturing, and in particular, electrohydrodynamic jet printing, has the potential to revolutionize 3D, functional, micro-scale device fabrication. Limiting this step change in manufacturing capabilities is the reliance of micro-scale Additive Manufacturing systems on a process monitoring, regulation, and quality control paradigm that is performed post-process and in an ad hoc manner. This research will break this open-loop paradigm by generating fundamental scientific knowledge in two areas: 1) the synthesis of a controls theoretic framework to compensate for spatial disturbances with a robust and computationally efficient learning-based algorithm and 2) the study of interactions between charged jets of materials and substrates in electrohydrodynamic jet printing using first principles physics models and validated by empirical studies leveraging a novel integration of electrohydrodynamic jet printing and atomic force microscopy. This research will contribute the fundamental knowledge required to transform 3D micro-scale Additive Manufacturing from a nascent, open-loop and ad hoc technology set to a fully automated, accurate, and robust closed-loop system.

添加剂制造系统（通常称为3D打印机）有望在许多中级应用中取代常规制造运营（尺寸为1到100毫米的零件）。同样，在微观尺度上的3D打印（尺寸为0.001至0.1毫米）具有彻底改变生物和化学传感器和集成电路原型和制造的方式。 3D打印机一次通过沉积一层薄层材料来建立复杂的零件。电水动力喷气机或电子喷射是此过程的有前途的微型版本。该项目将向标准的电子喷气式打印机添加传感器，并应用创新的控制法以极大地提高所得部分的精度。控制定律基于这样的观察，即3D打印特征通常从一层变为另一层的变化很小。通过观察层如何偏离所需形状，可以修改基线电子喷射控制以提高下一层的准确性。在这个项目中，将与电子喷射打印机集成原子力显微镜，以测量每一层的形状。为了更好地纠正打印过程，还将测量每一层周围的电场。技术研究计划与教育外展计划集成，以启动本科“微型制造商”俱乐部，并基于基于定制的微电路和传感器的廉价墨水打印的开源，自下而上的运动。Microcro规模添加剂制造业，尤其是Electro Hardrodynodic Jet印刷品，具有革命性的3D型，Miccace，Microdro，Mic Microdo，Micrody scace，尤其是型号。限制制造能力的这一步骤的变化是微观添加剂制造系统依赖于过程监视，调节和质量控制范式，该范式以临时的方式执行。这项研究将通过在两个领域中产生基本科学知识来打破这种开放环境范式：1）控制控制的理论框架的合成，以通过材料和材料的材料和基本化学模型中的实质性验证质疑的新型算法进行研究来补偿空间干扰，以实现强大的计算有效学习的算法和2）研究，以研究的相互作用进行研究。电水动力学喷射印刷和原子力显微镜的整合。这项研究将为将3D微型添加剂制造从新生，开环和临时技术转换为设置为完全自动化，准确且强大的闭环系统所需的基本知识。