Transcript
--3D Printing and beyond Desktop manufacture and its application in scientific research
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Song Xu, Ph.D. Sr. Application scientist
Desktop Manufacturing Makes It Possible ADesktop manufacture Everybody can build!!
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Focus of this Presentation Exactly how useful is the 3D printing? What else beyond 3d printing?
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Recall the greatest inventions of ancient China 2 of 4 are about spread of knowledge
Paper
printing
gun powder
compass
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The trend of civilization is toward the spread of knowledge and technology Recommended reading (The World Is Flat)
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The trend of civilization is toward the spread of knowledge and technology, which empower individual toward equality • Road, highway, aircraft, high speed railway (transportation) • Language, literature, printing, phone, computer, internet (information) • Workshop, factory, ?? (manufacture)
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The last information revolutions: the industrialization of printing
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The the next information revolutions: desktop publishing
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Manufacture is undergoing similar path
Initial manufacture are done by the master hands
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For the past 100 years, mass production industry had little change: standardization, scale and efficiency
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Then comes the computer numerical controlled machines(CNC)
Emerging of computer controlled machines allows small scale production However, the computer controlled machining was very expensive Page
The basics of computer numerical controlled machines
Accurate precise step motors replaced capable hands, computer replaced machining procedures
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There is ongoing revolution in manufacturing: desktop machine that has PC GUI based operation
CNC water jet, CNC mill and CNC router Page
Several different kinds of ordinary CNC machines
CNC lathe
CNC laser
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CNC 3D printer
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And the low cost CNC machines
$3000 CNC Mill
$1000 CNC laser $700 CNC Mill Page
Desk top manufacture is the an ongoing revolution
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3D printing : precision adding of material
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3D printing : precision adding of material
melting
Photo sensitive polymer
add glue to powder
laser melting Page
The limitation of 3D printing: lack of control of material property
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Problems of 3D printing
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Other affordable desktop production tools
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CNC laser cutting
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CNC laser cutting and its advantage
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CNC laser cutting and its advantage: pure 2D design easy to learn
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CNC laser cutting and its advantage: pure 2D design easy to learn
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The ultimate 3D machining: 5 axis CNC mill Suggested reading: go to www.youtube.com search for 5 Axis CNC art, watch this video
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The basics to learn desktop manufacturing: start with CAD
Group/Presentation Title Agilent Restricted
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The basic of CAD: turn an idea to a precised defined 3D drawing
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The basic of CAD: turn an idea to a precised defined 3D drawing
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What is CAM? (computer aided manufacture) CAM turn a designed shape into a machine tool path code (G code)
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Easy to learn and sometimes free trial amateur CAM
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CAM turns a designed shape into reality
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CAM turns a designed shape into reality
Step 1：design of 2D vector
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CAM turns a designed shape into reality
Step 2: define the depth of each cutting Page
CAM turns a designed shape into reality
Step 3: machine code tool paths generation by computer
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CAM turns a designed shape into reality
Step 3: simulation of machine tool path
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CAM turns a designed shape into reality
Step 3: simulation of machine tool path
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CAM turns a designed shape into reality
Step 4: actual cutting of a 2.5D part
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CAM design of a part with complicated curved shape
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CAM design and machining of a thin metal sheet
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CAM design and machining of a thin metal sheet leads us to the invention of sample holder for soft biological tissue samples
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CAM design and machining of part made of soft materials
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CAM design and machining of part made of soft materials
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See what a desktop CNC mill can do in 30 min
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My basement factory (total cost $7000)
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Examples of idea turned into prototype fast !
It s great! Or is it?
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Fixing foil for biological tissue type of sample: Suited to fix very soft sample that are thick inside a dish, or fluid cell
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Rock type sample fixing foil: Fix a thick sample inside a dish for fluid imaging
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Hydrophobic flat liquid cell: liquid cell does not have raised edge. Easy to view tip-sample distance. Liquid contained by hydrophobic surface tension
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Disposable PTFE liquid cell used with microscopic glass slide. PTFE naturally adhere to glass to form a liquid cell
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Sample holder for contact lens
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Single piece liquid cell: non-leaking design with bottoms. Can be machined to contain samples such as mica or HOPG. Tight fit cutout hold HOPG in place
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Square sample liquid cell (for 22mm microscope cover slip)
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Sample holder for single fiber/hair
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Liquid cell for fiber/hair type sample: hair sample wrap around the copper frame. A square tension ring push sample against the bottom. Domed cell bottom for fiber sample support. Illumination help tip to locate sample Page
Sample holder for precious metal bead single crystal
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Side mount sample holder for AFM
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Stading mount sample holder for AFM
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LED modulated illumination sample holder: LED power provided by controller, illumination switchable between bottom illumination and side illumination
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Optical fiber Amplitude modulated illumination sample holder: liquid crystal shutter modulation signal provided by AC controller
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Sample stage with controlled illumination This sample stage with controlled illumination module consist the following parts: 1. A liquid crystal shutter the controls the light from the light source. The shutter can be programmed to release a set time by sending a square wave, or it can be set to modulated with a sine wave. A regular liquid crystal shutter has a response frequency of 1000 Hz, Page high speed shutter can perform 10000Hz. 2. Liquid filled optical fiber to guide the light into the sample stage. 3. Two different sample stage design, back illumination for transparent sample and side illumination for nontransparent samples to be used on AFM
Laser illuminator with beam splitter and photodetector
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An electrical chemical cell for 5500 AFM: designed to be used inside a glove box. There is no handling of small parts. Sample stage built using PTFE. All parts are low cost and can be replaced
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Sample ultrasonic modulation stage 1. Thin film piezo stack oscillating the sample between 200Hz to 6MHz. AFM tip detects the oscillation amplitude and phase of local area, and shows contrast due to difference of sample softness and viscosity. 2. A special small liquid cell can be mounted
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Sample ultrasonic modulation stage for liquid cell and petridish 1. Thin film piezo stack oscillating the sample between 200Hz to 6MHz. AFM tip detects the oscillation amplitude and phase of local area, and shows contrast due to difference of sample softness and viscosity. 2. Can be used with 35mm dish, and specially designed liquid cell。
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Polymeric gel containing fiber structures imaged with Sample modulation 2
Image size 8 µm
topography
amplitude
phase
kH z 144.7
154.2
unpublished work by Lu Lu (Garno Group), LSU, Baton Rouge
163.8
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Fluid heat exchange cooling stage Using heat exchange fluid such as water or ethanol, cooled or heated fluid passively manipulated the temperature of sample cell.
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Sample holder for parallel magnetization
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Sample holder for parallel magnetization
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A +- 8000 gauss magnetic field inside the gap
Side view optical microscope for 5500 AFM
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A few words about Keysight Techology AFM
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Vacuum popping sample holder Vacuum operated sample holder allow the sealed sample to be transferred from glove box to SEM and the cover is opened by vacuum.
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Slipper locker 22mm cover slip can be washed and processed in the locker. No glue or screws are used. All parts assembled with friction
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Slipper rack Sample of various sizes can be loaded and washed, designed to be fit inside a beaker No glue or screws used to assemble Rack made of Acetyl/teflon blend
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Nano crystal sensor research kit: inter-digited electrode and small volum gas testing chamber
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