Research on Rapid Prototyping Using Functional Materials

从三维CAD几何数据自动、快速地制造出各种形状的实体的技术被称为快速成型技术。本研究的目的是提出一种利用弹性、导电性等多种不同性质的材料进行快速成型的基本技术，从而使得到的实体既具有一定的功能，又具有一定的几何特性。本论文的研究结果总结如下：1.通过对各种固体自由曲面制备方法的比较，选择了熔融沉积成型方法，因为该方法具有广泛的材料利用率。经过理论计算和基础实验，设计并制作了一套基于有限差分螺杆和柱面挤压的快速成型系统。该系统有多套螺杆和气缸，每套螺杆和气缸含有不同的材料。该系统在加工过程中选择螺杆-圆柱体，这样就可以加工出由多个…组成的固体物体。更多的术语2.用于快速成型的传统数据格式，如STL(立体光刻)，最初并不是为处理多种材料而设计的。通过扩展对现有STL和VRML(虚拟现实建模语言)格式的解释，以保持现有数据格式之间的兼容性，提出了一种新的适用于多种材料、制造的数据处理方法。在制造由多种材料组成的物体时，在某些材料组合中，边界上的两种材料之间的结合不够牢固。为了加强粘接，提出了相邻两层材料的路径重叠法和两层不同材料的路径交错法。上述方法已作为快速原型系统实现。通过制作由聚丙烯、弹性体和导电树脂等多种材料组成的对象，考察了本研究的有效性、可能性和电流限制。较少

Technologies to fabricate solid objects of various shapes automatically and rapidly from 3-D CAD geometry data are called "rapid prototyping". The purpose of this study is to propose a fundamental technology of rapid prototyping using multiple materials of different properties such as elasticity and electric conductivity so that the resulting solid objects have some functions as well as geometry. The results of this study are summarized as follows :1. By comparing solid freeform fabrication methods, fused deposition modeling (FDM) was adopted because of its capability of utilizing wide range of materials. After some theoretical calculation and basic experiments, a rapid prototyping system based on FDM using extrusion by screws and cylinders was designed and made. The system has multiple sets of screw and cylinder, each of which contains different materials. The system selects the screw-cylinder during fabrication process so that it can fabricate a solid object consisting of multiple ma … More terials.2. Conventional data formats for rapid prototyping such as STL (STereo-Lithography) are not originally designed to handle multiple materials. This study proposed a new data processing method for multiple material, fabrication by extending' the interpretation of existing STL and VRML (Virtual Reality Modeling Language) format so that the compatibility between current data formats is maintained.3. When fabricating an object consisting of multiple materials, bonding between two materials at the boundary is not strong enough in some material combination. To strengthen the bonding, path overlapping method for neighboring, two materials in the same layer and path interlace method for two layers of different materials were proposed.4. The methods mentioned above were implemented as a rapid prototyping system. By fabricating objects consisting of multiple materials such as polypropylene, elastomer and conductive resin, efficacy, possibility and current limitation of this study were examined. Less