C. P. Purssell

Using a magnetite/thermoplastic composite in 3D printing of direct replacements for commercially available flow sensors

Flow sensing is an essential technique required for a wide range of application environments ranging from liquid dispensing to utility monitoring. A number of different methodologies and deployment strategies have been devised to cover the diverse range of potential application areas. The ability to easily create new bespoke sensors for new applications is therefore of natural interest. Fused deposition modelling is a 3D printing technology based upon the fabrication of 3D structures in a layer-by-layer fashion using extruded strands of molten thermoplastic. The technology was developed in the late 1980s but has only recently come to more wide-scale attention outside of specialist applications and rapid prototyping due to the advent of low-cost 3D printing platforms such as the RepRap. Due to the relatively low-cost of the printers and feedstock materials, these printers are ideal candidates for wide-scale installation as localized manufacturing platforms to quickly produce replacement parts when components fail. One of the current limitations with the technology is the availability of functional printing materials to facilitate production of complex functional 3D objects and devices beyond mere concept prototypes. This paper presents the formulation of a simple magnetite nanoparticle-loaded thermoplastic composite and its incorporation into a 3D printed flow-sensor in order to mimic the function of a commercially available flow-sensing device. Using the multi-material printing capability of the 3D printer allows a much smaller amount of functional material to be used in comparison to the commercial flow sensor by only placing the material where it is specifically required. Analysis of the printed sensor also revealed a much more linear response to increasing flow rate of water showing that 3D printed devices have the potential to at least perform as well as a conventionally produced sensor.

Rapid manufacture of monolithic micro-actuated forceps inspired by echinoderm pedicellariae

The concept of biomimetics and bioinspiration has been used to enhance the function of materials and devices in fields ranging from healthcare to renewable energy. By developing advanced design and manufacturing processes, researchers are rapidly accelerating their ability to mimic natural systems. In this paper we show how micro-actuated forceps inspired by echinoderm pedicellarie have been produced using the rapid manufacturing technology of micro-stereolithography. The manufactured monolithic devices are composed of sets of jaws on the surface of thin polymer resin membranes, which serve as musculature for the jaws. The membranes are suspended above a pneumatic chamber with the jaws opened and closed through pneumatic pressure changes exerted by a simple syringe. The forceps can be used for tasks such as grasping of microparticles. Furthermore, when an object is placed in the centre of the membrane, the membrane flexes and the jaws of the device close and grasp the object in a responsive manner. When uncured liquid photopolymer is used to actuate the devices hydraulically instead of pneumatically, the devices exhibit self-healing behaviour, sealing the damaged regions and maintaining hydraulic integrity. The manufactured devices present exciting possibilities in fields such as micromanipulation and micro-robotics for healthcare.

Rapid prototyping technologies for ultrasonic beam focussing in NDE

This paper describes a technique where ultrasonic beam-modifying elements (acoustic lenses) have been designed in CAD, and then fabricated using rapid-prototyping techniques. An example of such a lens (resembling a miniature Schmidt-Cassegrain telescope) has been fabricated, and has been successfully used with a standard, commercially available ultrasonic transducer for imaging. Examples of images taken of a coin are given. Details of the design, build, performance and analysis of this focusing system are described.

Fabrication and analysis of cylindrical resin AFM microcantilevers

In this paper a new method of fabricating cylindrical resin microcantilevers using the Direct Digital Manufacturing (DDM) technique of Micro-stereolithography (MSL) is described. The method is rapid and commercially viable, allowing the fabrication of atomic force microscope (AFM) cantilevers which exhibit much larger spring constants than those currently commercial available. This allows for experimentation in a force regime orders of magnitude higher than currently possible using the AFM. This makes these cantilevers ideally suited for AFM-based depth sensing indentation. Due to their geometry, the assumptions used in the standard Euler-Bernoulli beam theory usually used to analyse AFM cantilevers may no longer be valid. Therefore approximate analytical solutions based on Timoshenko beam theory have been derived for the stiffness and resonant frequency of these cantilevers. Prototypes of the cantilevers have been fabricated and tested. Results show good agreement between experiment and theory.

Additive manufacture of impedance matching layers for air-coupled ultrasonic transducers

A key problem in designing an efficient ultrasonic transducer for operating in a low acoustic impedance medium such as air is the large impedance mismatch between the active piezoceramic material and the load medium. While acoustic matching layers can be added to the face of the piezoceramic, the associated manufacturing difficulties and reliability can impact upon the cost and longevity of the resultant transducer. This paper presents some preliminary investigations conducted using an additive manufacturing technique, to develop a new material system for matching layer fabrication for air-coupled ultrasonic transducers. Results to date are very encouraging, and could result in a robust, reproducible, economical and improved fabrication method for air-coupled transducers.