Jean-Claude Léon臺灣大學:機械工程學研究所廖昭仰Liao, Chao-YaugChao-YaugLiao2010-06-302018-06-282010-06-302018-06-282008U0001-1905200822251700http://ntur.lib.ntu.edu.tw//handle/246246/187026近幾年來，一種由雙光子吸收理論衍生出的雙光子聚合(TPP)微加工技術，因具有製造任意形狀且複雜之三維微結構的能力而逐漸受到矚目。觀察目前的研究，其趨勢已逐漸從製造最小可能特徵來擴展應用領域層面，轉變成針對提高其製造良率與/或效率等較實用方面上。本論文從電腦輔助設計/電腦輔助製造(CAD/CAM)的觀點，提出一個基於TPP微加工技術之微產品模型建立與模擬的完整解決方案。進行TPP的製造特性分析及考量微結構外型限制與功能需求之後，其結果顯示出此類物品的數位模型需要能表示出non-manifold拓樸結構的特徵。考量上述需求及指出目前缺乏實用軟體的現實之下，對於那些創造於設計室的產品，本文提出一套non-manifold模型準備方案。將來自於STEP檔案的CAD模型予以網格化後，再用數個多面體次區域來構成一個non-manifold模型。至於若產品已存在的話，其數位模型可以使用逆向工程技術得到。然而目前絕大部分目前所使用的方法只重建了物品外型而未還原其本身顏色。因此，本文提出一套可重建三維彩色模型之整合掃瞄程序。避免因過度聚合導致產生的微結構毀壞及因反射率不同導致聚合體大小不一，在藉助三維製造設備的幫助下，本文分別發展出一套雙維切層方法及專屬的雷射掃瞄路徑之規劃程序。上述兩方法同時亦可以增加加工效率。此外為加強微結構的強度，本文以焊接與雙輪廓概念發展出兩種方法，用來強化各次區域之連接強度與增加結構壁厚。後，數個數位微結構(包含non-manifold結構)以本文所提出方法實際用TPP微加工技術製造出來，來展示本論文所提出的方法之效能。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.Abstract xviiiésumé xxi 要 xxiiintroduction 1hapter 1 State of art of micro-product fabrication and their integration in a design process 5.1 Two-photon polymerization micro-manufacturing technique 5.1.1 The principle of TPP 5.1.2 Spatial resolutions (Voxel) of the TPP process 9.1.3 Comparison between TPP and general silicon-based micromachining technologies 11.1.4 Main technological characteristics of the micro-product manufacturing process with TPP 13.1.5 Process flow of TPP micro-fabrication through the concept of product view 17.2 Analysis of existing approaches for TPP micro-fabrication 19.2.1 TPP applications for families of micro-products 20.2.2 Integrated manufacturing systems for the TPP process 22.3 Layered Manufacturing (LM) 24.3.1 Staircase effect and deposition inaccuracies in a LM process 25.3.2 Other micro-manufacturing processes using LM technique 27.4 Geometric representations for a product model 30.4.1 Boundary representation (B-Rep) 31.4.2 Non-manifold representation 33.4.3 Polyhedral representation 35.5 Major data exchange formats 38.5.1 Stereo Lithography (STL) 38.5.2 STandard for the Exchange of Product model data (STEP) 41.6 CAD model of components obtained through a reverse engineering process 44.7 Texture mapping a component 47.8 Simulation operations for TPP micro-fabrication 49.8.1 Basic intersection algorithms 49.8.2 Laser beam trajectory planning strategies 50.8.3 Critical issues for preventing microstructure collapses brought by CSM 51.8.4 Critical issues of a slicing process brought by CSM 53.8.5 Issues related to scanning path planning 55.9 Conclusion 57hapter 2 Product view interface for color models acquired through a reverse engineering process 61.1 Introduction 61.2 Laser scanning without destroying the color information of an object 62.3 Automation of texture map generation 66.4 Orientation between a polyhedral model and a texture space 71.4.1 Perspective mapping 72.4.2 Scale orientation mapping 73.4.3 Texture mapping criteria 76.4.4 Texture filtering 80.5 An integrated scanning system for reconstructing color models of objects 82.6 Application example 85.7 Conclusion 87hapter 3 Product view Interface for TPP micro-manufacturing of non-manifold models 89.1 Introduction 90.2 Combining micro-product shapes and functions within the TPP fabrication process 93.3 High level topology and mixed shape representation 98.3.1 The concept of High Level Topology (HLT) 99.3.2 The concept of mixed shape representation 104.4 The software environment for the model preparation process 107.5 The manufacturing model preparation process 110.5.1 Interactive Merger Specification (IMS) process 112.5.2 Overlap Boundary Curve Determination (OBCD) process 117.6 Tessellation of a non-manifold product model 119.7 Conclusion 127hapter 4 Product view simulation process for TPP micro-manufacturing 129.1 Introduction 129.2 Laser beam trajectory path obtained from slicing a polyhedral model 130.3 Voxel overlap ratio and layer thickness criterion 132.4 Two-dimensional slicing process for non-manifold model 137.4.1 Adaptive slicing process (primary slicing phase) 141.4.2 Global 3D hatching process (secondary slicing phase) 144.4.3 Wire direct-writing process 147.5 Operators for enhancing the microstructure stiffness 147.5.1 Welding sub-domains 148.5.2 Double contours 151.6 Trajectory path planning 153.6.1 Focal distance criterion to characterize laser beam trajectories 153.6.2 Voxel exposure position 156.6.3 Fabrication Time 162.7 The slicing data structure 164.8 Conclusion 172hapter 5 Micro-products fabricated by TPP 175.1 The micro-fabrication set-up 175.2 The correction of voxel exposure time 177.3 The overall processing flow for the TPP micro-fabrication 180.4 Objects with simple shapes 183.5 Objects with complex shapes 187.6 Objects as non-manifold functional microstructures 191.7 Conclusion 194hapter 6 Conclusions and perspectives 197.1 Conclusions 197.2 Perspectives 199eferences 201ppendix A Basic intersection algorithms 21512787397 bytesapplication/pdfen-US微加工雙光子吸收聚合non-manifold物品二維切層三維彩色模型重建層加工逆向工程Micro-manufacturingTwo-photon polymerizationNon-manifold objectsTwo dimensional slicing3D color model reconstructionLayered manufacturingReserve engineeringthesishttp://ntur.lib.ntu.edu.tw/bitstream/246246/187026/1/ntu-97-D89522030-1.pdf