MRI: Development of a Multiscale Additive Manufacturing Instrument with Integrated 3D Printing and Robotic Assembly

MRI：开发具有集成 3D 打印和机器人装配功能的多尺度增材制造仪器

• 批准号: 1828355
• 负责人: Dan Popa
• 金额: $ 153.02万
• 依托单位: University of Louisville Research Foundation Inc
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2018
• 资助国家: 美国
• 起止时间: 2018-09-15 至 2021-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1828355&HistoricalAwards=false
• 关键词: MRI; Development; Multiscale; Additive; Manufacturing

In this project, the Nexus, a new instrument enabling robotic manufacturing for complex systems spanning dimensional scales between 1:1000 of an inch and 1 foot, will be developed. The proposed infrastructure will be located at University of Louisville's regional NSF National Nanotechnology Coordinated Infrastructure site in order to facilitate US researcher access to unique robotic assembly and additive manufacturing capabilities. The Nexus will contribute novel hardware and software for rapid prototyping of emerging microsystems, microrobots, wearable sensors, and multimaterial nanoscale systems. This project will pave the way for the physical realization of future advanced technology prototypes, such as hand-held microfactories for micro and nano technology, the next generation soft robots, and higher performance solar energy conversion systems. Engineering students using this MRI infrastructure will be exposed to an education environment that emphasizes precision robotics, microelectromechanical systems (MEMS) and advanced manufacturing skills. Imparting this knowledge to graduates is invaluable in keeping manufacturing jobs and startup companies in the U.S., since labor costs are not a factor when harnessing the potential of autonomous micromachines. The Nexus will be capable of multidimensional 100 nanometer positioning accuracy over meter distances for manufacturing of millimeter to computer tablet-sized integrated systems. Innovative custom process capabilities on the Nexus will include: 1) a fiber loom substation for smart fabrics, wearable sensors and soft robots, 2) 3D robotic microassembly alongside aerosol jetting thin film deposition capability for microrobots, in-situ packaged microsystems, and robot sensor skins, 3) a custom ultrasonic metal-polymer printing on robotic positioners for novel multimaterial plasmonic and bio-sensors, and 4) a photonic sintering station for nanostructured thin films. The design of Nexus will be carried out with in-house simulation tools using evolutionary search methods from design databases, in order to 1) reduce project risks, 2) guarantee high-yield manufacturing, and 3) optimize the system cost. The design framework will guide the development of Nexus software for the automation of robotic transfer motions between substations, intelligent process control, and more intuitive human-machine interfaces.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

在该项目中，将开发 Nexus，这是一种新仪器，可实现尺寸范围从 1:1000 英寸到 1 英尺之间的复杂系统的机器人制造。拟议的基础设施将位于路易斯维尔大学的地区 NSF 国家纳米技术协调基础设施站点，以方便美国研究人员获得独特的机器人组装和增材制造能力。 Nexus 将为新兴微系统、微型机器人、可穿戴传感器和多材料纳米级系统的快速原型设计提供新颖的硬件和软件。该项目将为未来先进技术原型的物理实现铺平道路，例如用于微米和纳米技术的手持式微型工厂、下一代软机器人以及更高性能的太阳能转换系统。使用该 MRI 基础设施的工科学生将接触到强调精密机器人技术、微机电系统 (MEMS) 和先进制造技能的教育环境。向毕业生传授这些知识对于在美国保留制造业工作和初创公司至关重要，因为在利用自主微型机器的潜力时，劳动力成本不是一个因素。 Nexus 将能够在数米距离内实现多维 100 纳米定位精度，用于制造毫米级到平板电脑大小的集成系统。 Nexus 上的创新定制工艺能力将包括：1）用于智能织物、可穿戴传感器和软机器人的纤维织机变电站，2）3D 机器人微装配以及用于微型机器人、原位封装微系统和机器人传感器的气溶胶喷射薄膜沉积能力皮肤，3）机器人定位器上的定制超声波金属聚合物印刷，用于新型多材料等离子体和生物传感器，以及4）用于纳米结构薄层的光子烧结站电影。 Nexus 的设计将通过内部仿真工具使用设计数据库中的进化搜索方法进行，以便 1）降低项目风险，2）保证高产量制造，3）优化系统成本。该设计框架将指导 Nexus 软件的开发，以实现变电站之间机器人传输运动的自动化、智能过程控制和更直观的人机界面。该奖项反映了 NSF 的法定使命，并通过使用基金会的评估进行评估，认为值得支持。智力价值和更广泛的影响审查标准。

项目成果

Adhesive Deposition Process Characterization for Microstructure Assembly

微结构组装的粘合剂沉积工艺表征

• DOI: 10.1115/msec2021-63929
• 发表时间: 2021
• 期刊: 16th International Manufacturing Science and Engineering Conference
• 作者: Sherehiy, Andriy;Montenegro, Andres;Wei, Danming;Popa, Dan O.
• 通讯作者: Popa, Dan O.

Modeling and Fabrication of Scalable Tactile Sensor Arrays for Flexible Robot Skins

• DOI: 10.1109/jsen.2019.2915362
• 发表时间: 2019-09-01
• 期刊: IEEE SENSORS JOURNAL
• 影响因子: 4.3
• 作者: Saadatzi, Mohammad Nasser;Baptist, Joshua R.;Popa, Dan O.
• 通讯作者: Popa, Dan O.

Functional Fiber Junctions for Circuit Routing in E-Textiles: Deterministic Alignment of MEMS Layout With Fabric Structure

用于电子纺织品中电路布线的功能性光纤接头：MEMS 布局与织物结构的确定性对准

• DOI: 10.1115/msec2021-63887
• 发表时间: 2021
• 期刊: 16th International Manufacturing Science and Engineering Conference
• 作者: Challa, Sushmita;Islam, M. Shafquatul;Wei, Danming;Beharic, Jasmin;Popa, Dan O.;Harnett, C. K.
• 通讯作者: Harnett, C. K.

SolarPede: a stick-and-slip, light-powered, Mobile micro-crawler

• DOI: 10.1007/s12213-020-00131-6
• 发表时间: 2020-06
• 期刊: Journal of Micro-Bio Robotics
• 影响因子: 2.3
• 作者: Ruoshi Zhang;Jordan F. Klotz;Danming Wei;Zhong Yang;A. Sherehiy;M. Saadatzi;D. Popa

Rapid fabrication of perovskite solar cells through intense pulse light annealing of SnO2 and triple cation perovskite thin films

• DOI: 10.1016/j.matdes.2019.108237
• 发表时间: 2020-01-05
• 期刊: MATERIALS & DESIGN
• 影响因子: 8.4
• 作者: Ghahremani, Amir H.;Martin, Blake;Druffel, Thad
• 通讯作者: Druffel, Thad