Randall F. Lind

Structure and mechanical behavior of Big Area Additive Manufacturing (BAAM) materials

Purpose This paper aims to investigate the deposited structure and mechanical performance of printed materials obtained during initial development of the Big Area Additive Manufacturing (BAAM) system at Oak Ridge National Laboratory. Issues unique to large-scale polymer deposition are identified and presented to reduce the learning curve for the development of similar systems. Design/methodology/approach Although the BAAM’s individual extruded bead is 10-20× larger (∼9 mm) than the typical small-scale systems, the overall characteristics of the deposited material are very similar. This study relates the structure of BAAM materials to the material composition, deposition parameters and resulting mechanical performance. Findings Materials investigated during initial trials are suitable for stiffness-limited applications. The strength of printed materials can be significantly reduced by voids and imperfect fusion between layers. Deposited material was found to have voids between adjacent beads and micro-porosity within a given bead. Failure generally occurs at interfaces between adjacent beads and successive layers, indicating imperfect contact area and polymer fusion. Practical implications The incorporation of second-phase reinforcement in printed materials can significantly improve stiffness but can result in notable anisotropy that needs to be accounted for in the design of BAAM-printed structures. Originality/value This initial evaluation of BAAM-deposited structures and mechanical performance will guide the current research effort for improving interlaminar strength and process control.

Mesofluidic actuation for articulated finger and hand prosthetics

The loss of fingers and hands severely limits career and lifestyle options for the amputee. Unfortunately, while there have been strides made in advancements of upper arm and leg prosthetics, the state of the art in prosthetic hands is lagging far behind. Options are generally limited to claw like devices that provide limited gripping capacity. The overall objective of this paper is to demonstrate a path towards a low-cost prosthetic hand with multiple articulated fingers and a thumb that rivals the human hand in terms of weight, size, dexterity, range of motion, force carrying capacity and speed. We begin with a description of the functional requirements for a human hand. When comparing requirements with actuation technologies, the fluid power approach has the potential to realize a prosthetic hand that rivals a human hand in size, strength and dexterity. We introduce a new actuation technology, mesofluidics, that focuses on miniaturization of fluid power to the meso-scale (mm to cm). As a novel demonstration of the potential for this technology, we describe a proof-of-principle mesofluidic finger that has intrinsic actuation and control (actuators and control valves within the volume of the finger). This finger weighs 63 grams, is sized to the 50th percentile male finger, has a total of 25 mechanical parts and is capable of providing 10 kg (22 lbs) of pinch force.

Multi-axis foot reaction force/torque sensor for biomedical applications

To support an Oak Ridge National Laboratory programs exoskeleton project, a unique multi-axis foot force/torque sensor was constructed and tested that has biomedical application such as clinical gait analysis. The challenging aspect of this multi-axis force sensor is that it had to conform to the bending of the human foot, withstand high impact loads, have high force sensitivity, feel comfortable to the human wearer, be integrated into a military style boot, measure the forces on the human foot when either the ball or the heel of the foot is in contact with the ground, respond to both positive and negative loading and have a low overall height and weight. This paper describes the design and testing of this unique sensor.

Modeling and testing of a novel piezoelectric pump

While there is a wide range of actuation technologies, none currently rivals the overall performance (power density, bandwidth, stress, stroke) of conventional hydraulic actuation [1]. It is well known in the actuation community that the power-to-weight ratios and the power-to-volume ratios of hydraulic actuators are, respectively, around 5 times and 10 to 20 times larger than comparable electric motors. Due to fundamental limitations in the magnetic flux density in the supporting structures and limitations in the heat transfer out of electric actuators, significant changes in these ratios are not likely in the near future [2]. Thermal limitations associated with electric motors do not apply to hydraulic actuators since the hydraulic fluid cools and lubricates the system. However, with all of these virtues, hydraulic actuators have serious practical implementation problems. Typically, servo-based hydraulic actuators are leaky and have generally poor energy efficiencies. This work addresses a new type of electric actuator that combines the best of both the electric and hydraulic mediums.

Development of a remote trauma care assist robot

In typical teleoperated surgeries, skilled staff are still necessary in the remote surgical room to change manipulator tooling and to manage surgical supply delivery and removal. This paper describes the development of a nurse robot to provide automated support to a teleoperated surgical manipulator system in environments where the presence of skilled surgical support staff may not be practical. The tools must be inserted precisely into a compliant manipulator in a timely manner, and the supplies are diverse in nature. To support experimental investigations and evaluations, a seven degrees-of-freedom commercially available manipulator was selected. The design of novel end-effectors, tool grasping and supply holding features, and tool auto-loading systems for optimum surgical tool changing and supply delivery in minimum time is presented. A novel approach for calibration of the nurse robot among compliant and rigid subsystems and for managing forces during subsystem interaction is described and experimental results using this force management approach are presented. Overall experimental performance data for the nurse robot system during tool changing and supply delivery tasks is also presented to illustrate the feasibility of performing these functions in a remote medical or trauma care-assist cell.

Design and Control of a Ship Motion Simulation Platform from an Energy Efficiency Perspective

Abstract Most hydraulic servo systems are designed with little consideration for energy efficiency. Pumps are selected based upon required peak power demands, valves are chosen primarily for their rated flow, actuators for the maximum force. However, the design of a hydraulic servo system has great potential in terms of energy efficiency that has, for the most part, been ignored. This paper describes the design and control of a large-scale ship motion simulation platform that was designed and built at Oak Ridge National Laboratory for the Office of Naval Research. The primary reasons to incorporate energy-efficiency features into the design are cost and size reduction. A preliminary survey of proposed designs based on traditional motion simulation platform configurations (Stewart Platforms) required hydraulic power supplies approaching 1.22 MW. This manuscript describes the combined design and control effort that led to a system with the same performance requirements, however requiring a primary power supply that was less than 100 kW. The objective of this paper is to illustrate alternative design and control approaches that can significantly reduce the power requirements of hydraulic systems and improve the overall energy-efficiency of large-scale hydraulically actuated systems.

Using Big Area Additive Manufacturing to directly manufacture a boat hull mould

ABSTRACT Big Area Additive Manufacturing (BAAM) is a large-scale, 3D printing technology developed by Oak Ridge National Laboratorys Manufacturing Demonstration Facility and Cincinnati, Inc. The ability to quickly and cost-effectively manufacture unique moulds and tools is currently one of the most significant applications of BAAM. This work details the application of a BAAM system to fabricate a 10.36 m (34 ft) catamaran boat hull mould. The goal of this project was to explore the feasibility of using BAAM to directly manufacture a mould without the need for thick coatings. The mould was printed in 12 individual sections over a five-day period. After printing, the critical surfaces of the mould were CNC-machined, the sections were assembled, and a final hull was manufactured using the mould. The success of this project illustrates the time and cost savings of BAAM in the fabrication of large moulds.