Sensing and Control of Photopolymerization-based Additive Manufacturing Processes

基于光聚合的增材制造工艺的传感和控制

• 批准号: 1234561
• 负责人: David Rosen
• 金额: $ 26.92万
• 依托单位: Georgia Tech Research Corporation
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2012
• 资助国家: 美国
• 起止时间: 2012-08-01 至 2016-07-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1234561&HistoricalAwards=false
• 关键词: Sensing; Control; Photopolymerization; based; Additive

The research objective of this award is to test the hypotheses that 1) an interferometery-based sensor can monitor the extent of polymerization throughout the irradiation area of a photopolymerization-based additive manufacturing process, 2) the sensor will enable measurement of cured part size, and 3) the sensor will enable feedback control of the process. Most additive manufacturing processes operate in an open-loop manner. In contrast, a novel interferometry-based sensor is investigated to monitor photopolymerization processes in real-time. The sensor will be integrated with a research Exposure Controlled Projection Lithography system to enable part fabrication. With this sensor, high resolution interrogation of polymerizing samples can be performed, enabling an understanding of the spatial and temporal distribution of polymerization rate and degree of cure as a function of process variables. A new model of photopolymerization will be tested that incorporates polymerization rate, inhibitor presence and diffusion, and shrinkage. The model will be used in the development of a new approach to process planning and to predict cured part size and shape. Feedback control capability will be developed that enables adjustments of photopolymerization extents in order to improve process precision and repeatability. If successful, this research could benefit society by enabling the manufacture of precision micro-optics devices that could not be fabricated economically by conventional processes. These devices could have applications in medical imaging, portable energy, photography, and metrology industries, among others. Graduate and undergraduate students from under-represented groups will be recruited for this project. The work will enhance the infrastructure for research and education by developing and maintaining facilities for photopolymerization sensing and control experiments and for part fabrication. Broad dissemination will be achieved through courses enhanced with research results, undergraduate research opportunities, active industry involvement, papers and presentations in engineering forums, and a web-site to report results and provide access to the developed additive manufacturing sensing and control system.

该奖项的研究目标是测试以下假设：1）基于干涉仪的传感器可以监测基于光聚合的增材制造工艺的整个照射区域的聚合程度，2）传感器将能够测量固化部件尺寸，以及3）传感器将能够对过程进行反馈控制。 大多数增材制造工艺以开环方式操作。 与此相反，一种新的干涉传感器进行了研究，以实时监测光聚合过程。 该传感器将与一个研究曝光控制投影光刻系统集成，使部分制造。 使用该传感器，可以进行聚合样品的高分辨率询问，从而能够理解聚合速率和固化度的空间和时间分布作为过程变量的函数。 将测试一种新的光聚合模型，该模型包括聚合速率、抑制剂的存在和扩散以及收缩。 该模型将用于开发一种新的工艺规划方法，并预测固化零件的尺寸和形状。 将开发反馈控制能力，使光聚合程度的调整，以提高工艺精度和可重复性。如果成功的话，这项研究可以通过制造传统工艺无法经济地制造的精密微光学器件来造福社会。 这些设备可以应用于医学成像、便携式能源、摄影和计量行业等。 该项目将招募来自代表性不足群体的研究生和本科生。 这项工作将通过开发和维护用于光聚合传感和控制实验以及部件制造的设施来加强研究和教育的基础设施。 广泛传播将通过增强研究成果的课程，本科生研究机会，积极的行业参与，工程论坛上的论文和演讲，以及报告结果并提供访问开发的增材制造传感和控制系统的网站来实现。