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List of Figures1.1 SDM process cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.2 SDM robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.3 SDM leg with embedded components . . . . . . . . . . . . . . . . . . 83.1 Crossboundary embedding objective . . . . . . . . . . . . . . . . . . . 203.2 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.3 Pre-encapsulation process example illustration . . . . . . . . . . . . . 283.4 Suspending fixture method . . . . . . . . . . . . . . . . . . . . . . . . 303.5 Process flowchart for the four main methods for partial and crossboundaryembedding . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.6 Selective material deposition . . . . . . . . . . . . . . . . . . . . . . . 343.7 Selective sacrificial material deposition . . . . . . . . . . . . . . . . . 353.8 String gimbal fabrication process . . . . . . . . . . . . . . . . . . . . 363.9 String gimbal photo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.10 Selective sacrificial material removal . . . . . . . . . . . . . . . . . . . 383.11 Spring joint fabrication process . . . . . . . . . . . . . . . . . . . . . 403.12 Spring joint photo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413.13 Photolithographical cross-boundary embedding process . . . . . . . . 423.14 Photolithographed product photo . . . . . . . . . . . . . . . . . . . . 433.15 Pre-encapsulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453.16 Three types of linkages . . . . . . . . . . . . . . . . . . . . . . . . . . 463.17 Pseudo-boundary formation . . . . . . . . . . . . . . . . . . . . . . . 483.18 Process selection flowchart . . . . . . . . . . . . . . . . . . . . . . . . 513.19 Process selection flowchart for direct cross-boundary embedding . . . 52xii
4.1 Coordinate system definition . . . . . . . . . . . . . . . . . . . . . . . 564.2 Load, deformation, major strain, and fiber location . . . . . . . . . . 614.3 Principal X strain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624.4 Principal Y strain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 634.5 Principal Z strain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644.6 FEA setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664.7 control FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704.8 a01 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 714.9 a02 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724.10 a03 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 734.11 a04 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 754.12 a05 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764.13 a06 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 774.14 a09 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 794.15 a11 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804.16 a12 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814.17 a16 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 824.18 a19 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 844.19 a21 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 854.20 a22 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 864.21 a23 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 874.22 a24 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894.23 a25 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904.24 b05 FEA results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 914.25 Relative stiffenings in Y bending and Z torsion . . . . . . . . . . . . . 934.26 Fabrication sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . 954.27 Prototype photo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 964.28 Comparison of FEA and test results for the control piece . . . . . . . 1004.29 Comparison of FEA and test results for a01 . . . . . . . . . . . . . . 1014.30 Comparison of FEA and test results for a02 . . . . . . . . . . . . . . 1034.31 Comparison of FEA and test results for a05 . . . . . . . . . . . . . . 105xiii
Page 1 and 2: DESIGN AND FABRICATION OF MULTIMATE
Page 3 and 4: I certify that I have read this dis
Page 5 and 6: or in bulk. Consideration of fabric
Page 7 and 8: my parents busy at home while I’v
Page 9 and 10: 2.2.1 Application, modeling, and th
Page 11: List of Tables3.1 Design and materi
Page 15 and 16: Chapter 1IntroductionJuu yoku gou w
Page 17 and 18: 31.1.1 Conventional fabricationOne
Page 19 and 20: 5referred to as sacrificial materia
Page 21 and 22: 7Figure 1.2: SDM robot featuring em
Page 23 and 24: 9stiffness limitations of flexures.
Page 25 and 26: Chapter 2Previous WorkIn order to p
Page 27 and 28: 132.1.2 Previous component embeddin
Page 29 and 30: 15have produced a very similar flex
Page 31 and 32: 17• bonding.The material is large
Page 33 and 34: 193.1 IntroductionThere are several
Page 35 and 36: 213.2.1 Materials and manufacturing
Page 37 and 38: 233.3 Partial and cross-boundary em
Page 39 and 40: 25• Bulk removal: Uncontrolled ma
Page 41 and 42: 27for the pre-encapsulation process
Page 43 and 44: 29Suspending fixture methodAnother
Page 45 and 46: 31Selective material removal takes
Page 48 and 49: 3412I-3I-4Create mold and fixturePl
Page 51 and 52: 37Figure 3.9: Finished mechanism wi
Page 53 and 54: 39that is anchored in solid polymer
Page 55 and 56: 41Figure 3.12: Photograph of the fi
Page 57 and 58: 43SU-8 (photocurable polymer)Embedd
Page 59 and 60: 45V-1V-2V-3V-4Create a tight mold f
Page 61 and 62: 47and risk elimination of flexible
Page 63 and 64:
49Pseudo-boundary formation Pre-enc
Page 65 and 66:
51STARTDesign / RedesignDirect boun
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53obstructed by it, and avoiding st
Page 69 and 70:
Chapter 4Stiffness modification of
Page 71 and 72:
57Let us assume the flexure to have
Page 73 and 74:
59The suggested fiber configuration
Page 75 and 76:
Figure 4.2: Each column illustrates
Page 77 and 78:
Figure 4.4: The cones in the lower
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65based on the strain condition at
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67effectively produce 18[Nmm] of to
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69The stiffness ratio between pitch
Page 85 and 86:
71rotY5.004.004.20rotY7653.002.001.
Page 87 and 88:
73rotY5.004.003.00rotY76542.001.001
Page 89 and 90:
75rotY5.004.003.00rotY76542.001.001
Page 91 and 92:
77rotY5.004.003.00rotY76542.001.001
Page 93 and 94:
79rotY5.004.003.004.49rotY76543.932
Page 95 and 96:
81rot Y5.00rot Y74.0065rot -X3.002.
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83the significant Y stiffening and
Page 99 and 100:
85rot Y5.00rot Y74.0065rot -X0.303.
Page 101 and 102:
87rot Y5.00rot Y7rot -X4.003.002.00
Page 103 and 104:
89rot Y5.00rot Y74.0065rot -X0.343.
Page 105 and 106:
91The strings are configuredas in a
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93a05a19a11a06a01ControlFigure 4.25
Page 109 and 110:
95Machine mold cavity for rigid end
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97largely prevented to simplify mea
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99Control piecePlease see figure 4.
Page 115 and 116:
101rotY5.00rotY74.003.002.001.004.2
Page 117 and 118:
103rot Y5.00rot Y74.006rot -X3.002.
Page 119 and 120:
105rotY5.004.003.004.49AnalysisrotY
Page 121 and 122:
107rotY5.004.003.004.82AnalysisrotY
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109for the geometric nonlinearity,
Page 125 and 126:
111X-bendY-bendZ-torsionControla01M
Page 127 and 128:
113Figure 4.37: Photograph of faile
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115evidence of elastomer infiltrati
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117elastomer, similar to those obse
Page 133 and 134:
Chapter 5Conclusion5.1 SummarySever
Page 135 and 136:
121via embedded wiring that runs ac
Page 137 and 138:
123Ashby, M. (1999). Materials Sele
Page 139 and 140:
125Cooper, A. (1999). Fabrication o
Page 141 and 142:
127Li, X., Stampfl, J., and Prinz,
Page 143 and 144:
129Nutt, K. (1991). Selective laser
Page 145 and 146:
131Stubbs, N. and Thomas, S. (1984)
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