CARNEGIE MELLON Department of Electrical and Computer EngineerJ Manufacturing Mechatronics Using a Recursive Mask and Deposit ( MD ) Process
A new technology for manufacturing mechatronics is described. The technique is based on recursive masking and deposition of thermally sprayed materials. Using these methods, structures can be created that embed and interconnect electronic components, resulting in highly integrated mechatronic devices. A simple, electromechanical artifact was designed and produced to assess the feasibility of these techniques. The details and limitations of this project are discussed and areas of future research are identified which are aimed at realizing the full potential of this emerging manufacturing process.
A Framework for Thermal Spray Shape Deposition: The MD* System
Abstrnct This paper present.s t.he framework for a solid-freeform-fabrication syst.em based on thermal spray shape deposition t.o build mult.i-mat.erial st.ruct.ures by incremen tal build-up of t.hin cross-sect.ional layers. The basis of theMD* System (recursively, Mask and Deposit.) is to spray each layer using disposable masks to shape each layer. A thermal spray approach has the potential to build dense parts with desirable mechanical properties. Metal. ceramic, plastic, laminate, and composite structures can be deposited. Since l11asking enables selective deposition wit.hin a layer, complet.e assemblies composed of different mat.erials can be creat.ed in a single process. For example, int.egrated electronic/mechanical structures are feasible.
Optimization of robotic trajectories for thermal spray shape deposition
Abstract: "Thermal spray shape deposition is a new process for fabricating net-shape parts by incremental material build-up of cross-sectional layers. This paper presents an approach for spraying thin, flat layers using a robotic spray system. Asymmetries of the spray distribution are first corrected by tilting the spray torch based upon a computer model of the measured spray distribution. The path of the torch is then found using heuristics which are based upon the estimated standard deviation of the corrected distribution. For example, thick arc sprayed coatings (i.e. ╠â4mm) have been deposited using this method with the resulting standard deviation from the mean thickness between 20to 30 [mu]m. To demonstrate the shape deposition process, a layered prototype turbine blade shape was built using these optimized trajectories."