Feature-Based Parametric Design of a Gating System for a Die-Casting Die

This paper presents a semi-automated approach for designing the gating system of a die-casting die. This approach combines the P-Q 2 technique and feature-based parametric design for achieving the automatic generation of the geometries for the gating system. It also enables users to integrate their expertise in the design at an early stage. User-defined gating features are pre-defined and stored in a gating library, and are then retrieved from the library and applied to the gating part with the desired parameters and locations during the design process. Algorithms based on the P-Q 2 technique are proposed for calculating the related parameters of the gating system. A prototype design has been developed using this approach, and the system is able to shorten the time for constructing the 3D geometries of the gating elements such as the gate, runner, overflow, shot sleeve, sprue, etc.     

Effects of poly(methyl methacrylate)‐based low‐profile additives on the properties of cured unsaturated polyester resins. II. Volume shrinkage characteristics and internal pigmentability

The effects of three series of self‐synthesized poly(methyl methacrylate) (PMMA)‐based low‐profile additives (LPAs), including PMMA, poly(methyl methacrylate‐co‐butyl acrylate), and poly(methyl methacrylate‐co‐butyl acrylate‐co‐maleic anhydride) with different chemical structures and MWs on the volume shrinkage characteristics and internal pigmentability for low‐shrink unsaturated polyester (UP) resins during curing were investigated by an integrated approach of static phase characteristics of the ternary styrene (ST)/UP/LPA system, reaction kinetics, cured‐sample morphology, microvoid formation, and property measurements. The relative volume fraction of microvoids generated during the cure was controlled by the stiffness of the UP resin used, the compatibility of the uncured ST/UP/LPA systems, and the glass‐transition temperature of the LPAs used. On the basis of the Takayanagi mechanical model, the LPA mechanism on volume shrinkage control, which accounted for phase separation and microvoid formation, and factors leading to both a good volume shrinkage control and acceptable internal pigmentability for the molded parts are discussed. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 91: 3388–3397, 2004     

Performance characterization of drop-on-demand micro-dispensing system with multi-printheads

Due to the diversity of printhead activation mechanism, printhead design and its operational parameters, integrating heterogeneous printheads is usually preferred in multi-material micro-fabrication tasks. However, evaluating the performance of multi-printhead micro-dispensing system is seldom investigated. In this paper, the developed micro-dispensing system performance along X and Y axes is discussed based on the attached two printheads, i.e. solenoid actuating micro-valve and piezoelectric printhead. Comprehensive experiments are conducted to characterize droplet size and their deposition performance on the substrate. To explore the optimal printing parameters (e.g. pitch and printing speed), the characterization results are analyzed in terms of deposition accuracy and line straightness, printable conditions, and stability. It can be concluded that an optimal pitch is the key to achieve better line straightness for micro-valve printhead. For normal printing using piezoelectric printhead, the selection of printing speed is determined in terms of pitch. A lower speed is recommended for both to minimize the disturbance from printheads’ point-to-point motion. In addition, some other factors’ influence on printing accuracy such as vibrations, printhead synchronization, printing time are discussed. Our study on the relationship between printing parameters and dispensing performance will not only benefit the optimization of micro-dispensing performance, but also the development of theoretical models or empirical equations in the 3D micro-fabrication process.     

Enhanced sample concentration on a three-dimensional origami paper-based analytical device with non-uniform assay channel

Traditional microfluidic paper-based analytical devices (μPADs) consist of a flat straight channel printed on a paper substrate. Such devices provide a promising low-cost solution for a variety of biomedical assays. However, they have a relatively high sample consumption due to their use of external reservoirs. Moreover, in μPADs based on the ion concentration polarization (ICP) effect, controlling the cross-sectional area of the Nafion membrane relative to that of the hydrophilic channel is difficult. Accordingly, the present study utilizes an origami technique to create a μPAD with a three-dimensional (3D) structure. The μPAD features short channels and embedded reservoirs, and therefore reduces both the driving voltage requirement and the sample consumption. Moreover, the preconcentration effect is enhanced through the use of an additional hydrophilic area adjacent to the Nafion membrane. The existence of electroosmotic flow (EOF) within the proposed device is confirmed using a current-monitoring method. In addition, the occurrence of ICP is evaluated by measuring the current–voltage response of the device at external voltages ranging from 0 to 50 V. The experimental results obtained for a fluorescein sample with an initial concentration of 10^?5 M show that a 100-fold enhancement factor can be achieved given the use of a non-uniform-geometry design for the assay channel and an additional hydrophilic region with an area equal to approximately 10% of the channel cross-sectional area. Finally, a 100-fold factor can also be achieved for a fluorescein isothiocyanate sample with an initial concentration of 10^?6 M given an external driving voltage of 40 V.     

Integration of topology and shape optimization for design of structural components

This paper presents an integrated approach that supports the topology optimization and CAD-based shape optimization. The main contribution of the paper is using the geometric reconstruction technique that is mathematically sound and error bounded for creating solid models of the topologically optimized structures with smooth geometric boundary. This geometric reconstruction method extends the integration to 3-D applications. In addition, commercial Computer-Aided Design (CAD), finite element analysis (FEA), optimization, and application software tools are incorporated to support the integrated optimization process. The integration is carried out by first converting the geometry of the topologically optimized structure into smooth and parametric B-spline curves and surfaces. The B-spline curves and surfaces are then imported into a parametric CAD environment to build solid models of the structure. The control point movements of the B-spline curves or surfaces are defined as design variables for shape optimization, in which CAD-based design velocity field computations, design sensitivity analysis (DSA), and nonlinear programming are performed. Both 2-D plane stress and 3-D solid examples are presented to demonstrate the proposed approach. Received January 27, 2000 Communicated by J. Sobieski     

Multipass hierarchical stereo matching for generation of digital terrain models from aerial images

This paper presents a new multi-pass hierarchical stereo-matching approach for generation of digital terrain models (DTMs) from two overlapping aerial images. Our method consists of multiple passes which compute stereo matches with a coarse-to-fine and sparse-to-dense paradigm. An image pyramid is generated and used in the hierarchical stereo matching. Within each pass, the DTM is refined by using the image pyramid from the coarse to the fine level. At the coarsest level of the first pass, a global stereo-matching technique, the intra-/inter-scanline matching method, is used to generate a good initial DTM for the subsequent stereo matching. Thereafter, hierarchical block matching is applied to image locations where features are detected to refine the DTM incrementally. In the first pass, only the feature points near salient edge segments are considered in block matching. In the second pass, all the feature points are considered, and the DTM obtained from the first pass is used as the initial condition for local searching. For the passes after the second pass, 3D interactive manual editing can be incorporated into the automatic DTM refinement process whenever necessary. Experimental results have shown that our method can successfully provide accurate DTM from aerial images. The success of our approach and system has also been demonstrated with a flight simulation software. Received: 4 November 1996 / Accepted: 20 October 1997     

A Six-sigma approach for benchmarking of RP&M processes

This paper presents a methodology of using six-sigma quality tools for benchmarking of rapid prototyping & manufacturing (RP&M) processes. It involves the fabrication of a geometric benchmark part and a methodology to control and identify the best performance of the process to reduce the variablity in the fabricated parts. The approach is demonstrated with a case study based on the direct laser sintering (DLS) process for prototyping using plastic powder. In the case study an identified set of six-sigma/ statistical process control tools is employed to determine and best tune factors affecting the desired outcomes of the built parts.     

Dephytinisation of rice bran and manufacturing a new food ingredient

Rice bran was extruded at 130 °C and a screw speed of 140 rpm for 20 s to inactivate lipase and prevent lipid oxidation. Although the extrusion process induced further complex formation between phytic acid and protein as well as between phytic acid and starch, nearly 94% of phytic acid in the extruded rice bran could still be removed by solid/liquid extraction conducted at 25 °C for 30 min using hydrochloric acid at pH 2 as solvent and a solvent/rice bran ratio of 15. After the extract had been neutralised and phytic acid removed, it was added back to the rice bran solid to replenish the nutritional and functional components of the solid. The mixture was then dried in a drum dryer to yield a powdered product. The dephytinised rice bran product contained most of the protein, fat, dietary fibre and B vitamins and more than 50% of the oryzanol originally present in the raw rice bran. © 2001 Society of Chemical Industry     

Direct laser sintering of a copper-based alloy for creating three-dimensional metal parts

Direct laser sintering of metal, as one of the important developments in rapid prototyping technologies, is discussed in this paper. A special copper-based alloy is used for this rapid prototyping process. Experiments on the sintering conditions of this material had been conducted in a self-developed high temperature metal sintering machine. The mechanism of laser sintering for this kind of material was disclosed by SEM analysis of microstructures of sintered parts. The density, surface roughness and mechanical properties of the laser sintering parts due to variation of process parameters were measured and analysed. The effect of process parameters to the accuracy of sintered parts was also investigated. Thus, optimum parameters were obtained for direct laser sintering of three-dimensional metal parts.     

Thermally and electrically switchable gratings based on polymer-ball-type polymer-dispersed liquid-crystal films

We focus on the fabrication and study of controllable holographic gratings based on azo-dye-doped and undoped polymer-ball-type polymer-dispersed liquid-crystal films. Experimental results indicate that the next step of photopolymerization of the sample with the illumination of Ar+ laser beams after UV curing causes a latent density grating to be recorded. This grating is formed by a selective secondary photopolymerization. Heating and applying a voltage change the structure of the liquid crystal and induce the appearance of the latent grating. Diffraction efficiencies versus temperature, voltage, and state of polarization are studied for both dye-doped and undoped cells and are found to be quite different. This discrepancy is attributable to the reorientation effect of liquid crystals through their interaction with the photo-induced adsorption of the doped dyes on the surface of polymer balls in the dye-doped cell.