Product Model Creation and Simulation for Two-photon Polymerization Micro-manufacturing
Date Issued
2008
Date
2008
Author(s)
Liao, Chao-Yaug
Abstract
Recently, the Two-Photon Polymerization (TPP) micro-manufacturing technology derived from two-photon absorption draws everyone’s attention because of its fabrication capability of arbitrary-shaped and complex three dimensional (3D) microstructures. According to my observation of current researches, the trends have gradually changed from fabricating smallest possible features to expanding its application domains toward more effective topics such as increasing fabrication quality and/or efficiency. This thesis proposes a micro-product model creation and simulation scheme for TPP micro-manufacturing from Computer-Aided Design/Computer-Aided Manufacturing (CAD/CAM) points of view.n analysis of TPP main features is performed to characterize its manufacturing capabilities. According to the analysis results and the incorporation of microstructure shape constraints and functional requirements, it is shown that the digital model of such objects should be able to describe non-manifold topological structure. Taking this requirement into account and pointing out the lacks of current practices, a non-manifold model preparation scheme is proposed for a product created at a design office. The CAD model imported from a STEP file is tessellated into several manifold polyhedral sub-domains forming a non-manifold polyhedron. Similarly, for an existing product, it can be reverse engineered to obtain its digital model. However, most of current approaches only reconstruct the object shape without its intrinsic colors. For this reason, an integrated scanning process is developed in this thesis in order to generate 3D colored models.o avoid the destruction of the microstructure caused by over polymerization and the inconsistent voxel sizes originated by variations of light reflections, a two-dimensional slicing process and a dedicated trajectory path planning are developed with the aid of the 3D capabilities of the manufacturing equipment. Hence, the fabrication efficiency can be increased by applying the two processes above. In addition, to improve the microstructure stiffness, two methods developed through the concepts of welding and double contours are used to strengthen the connections between sub-domains and increase their wall thickness, respectively.inally, to demonstrate the efficiency of the proposed approach, several digital microstructures, including non-manifold ones, are fabricated according to the proposed model preparation and processing scheme.
Subjects
Micro-manufacturing
Two-photon polymerization
Non-manifold objects
Two dimensional slicing
3D color model reconstruction
Layered manufacturing
Reserve engineering
Type
thesis
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