Building Block Synthesis of Self-Supported Three-Dimensional Compliant Elements for Metallic Additive Manufacturing

Danun, Aschraf N.; Palma, Philip Dalla; Klahn, Christoph; Meboldt, Mirko

doi:10.1115/1.4048220

Cited by 12 publications

(4 citation statements)

References 32 publications

(39 reference statements)

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“…Additive manufacturing (AM) allows CMs to be produced at a microscopic scale, which is impossible for rigid-body mechanisms due to their complexity. This also increases compliant mechanisms' portability over traditional mechanisms due to generally reduced size and lightweighting properties (Danun et al, 2020;Kiener et al, 2021).…”

Section: Compliant Mechanisms In Additive Manufacturingmentioning

confidence: 99%

A Dfam Framework for the Design of Compliant Structures

Air

Wodehouse

2023

Proc. Des. Soc.

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Additive manufacturing methods present prospects for designed mechanical deformation via the integration of controlled anisotropic lattice structure forms. Their assimilation into a Design for Additive Manufacturing (DfAM) process would create a novel framework for the design of compliant mechanisms (CM). The method uses lattice structures to replace rigid multi-part mechanisms, with integrated and controlled flexibility into a single, compact, and precise component. In recent years, a lot of research has gone into making algorithms that enable users to generate CMs for their designs. But by relying on algorithms to design solutions, are they neglecting to fully understand how these mechanisms work. This work undertakes the design and development of a novel DfAM Framework, that utilises controlled lattice structure deformations to create a standardised method of CM design. The authors have developed a method for this, whilst allowing users to tailor CMs to their design, by using a wide selection of pretested structures. Indicating suitable structures for their design using an integrated novel taxonomy. The framework is tested and developed using a series of case studies.

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Section: Compliant Mechanisms In Additive Manufacturingmentioning

confidence: 99%

A Dfam Framework for the Design of Compliant Structures

Air

Wodehouse

2023

Proc. Des. Soc.

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“…Metal 3D printing is a current method of fabricating metal compliant mechanisms, but the technology can result in component anisotropy, high production costs, and a discontinuous manufacturing process that present challenges in some applications [5]. However, there is some research starting to be done on improving additive manufacturing for metal compliant mechanisms [6]. Outside of additive manufacturing, metal is difficult to machine on the mesoscale, with electrical discharge machining (EDM) being one of the few viable options.…”

Section: Introductionmentioning

confidence: 99%

Laser Forming of Compliant Mechanisms

Ames

Smith

Lazarus

et al. 2023

ASME Open Journal of Engineering

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Small-scale flexible (or compliant) mechanisms are valuable in replacing rigid components while retaining comparable motion and behavior. However, fabricating such mechanisms on this scale (from 0.01 to 10 cm) proves difficult, especially with thin sheet metals. The manufacturing method of laser forming, which uses a laser to cut and bend metal into desired shapes, could facilitate this fabrication. However, specific methods for designing mechanisms formed by lasers need to be developed. This work presents laser forming as a means for creating compliant mechanisms on this scale with thin sheet metal. The unique challenges for designing mechanisms to be laser formed are explored, and new adaptations of existing designs are fabricated and discussed. The design of basic “building-block” features is developed for several mechanisms: a parallel-guided mechanism, a cross-axis flexural pivot, a lamina emergent torsional (LET) joint array, a split-tube flexure, and a bi-stable switch. These mechanisms are shown to perform repeatable behavior and motion comparable to existing nonlaser-formed versions. The further possibilities for fabricating compliant mechanisms with laser forming are explored, as advanced applications can benefit from using lasers to create compliant mechanisms from thin sheet metal.

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“…Cellular structures comprised of CM unit cells have been optimized for a desired compliance with the assumption of a linear displacement profile [22]. There are also FEA models that simulate the nonlinear deflection of compliant beam elements, considering Hookean material behavior [23]. In general, these FEA-based CM design methods consider large deformation behavior through geometric nonlinearity, but are limited to linear material behavior.…”

Section: Introductionmentioning

confidence: 99%