Optimal Pattern Design Research Articles

Comparative study of deposition patterns for DED-Arc additive manufacturing of Al-4046

Quality assurance is one of the largest challenges to the widespread adoption of metal additive manufacturing technology. Deposition pattern can significantly impact the temperature distribution during manufacturing process and thus the overall quality and residual stress formation of the manufactured components. In order to explore the intricate relationship, three different deposition patterns in DED-Arc additive manufacturing, the meander pattern, the spiral pattern and the newly developed S pattern, were experimentally and numerically scrutinized in terms of the resulting temperature distribution, grain size, porosity as well as residual stress formation. The study reveals that the variation of the deposition paths results in characteristic temperature fields and gradients with distinct local peak temperatures that determine the deposition quality, and simultaneously offers great degrees of freedom for optimal pattern design. Comparing the results with different deposition patterns, the S pattern leads to a more homogeneous temperature distribution, showing beneficial effects on the microstructure, porosity and residual stress formation in the deposited Al-4046 material, and is thus regarded as a promising alternative for improving additively manufactured parts quality.

GOBO projection for 3D measurements at highest frame rates: a performance analysis

Aperiodic sinusoidal patterns that are cast by a GOBO (GOes Before Optics) projector are a powerful tool for optically measuring the surface topography of moving or deforming objects with very high speed and accuracy. We optimised the first experimental setup that we were able to measure inflating car airbags at frame rates of more than 50 kHz while achieving a 3D point standard deviation of ~500 µm. Here, we theoretically investigate the method of GOBO projection of aperiodic sinusoidal fringes. In a simulation-based performance analysis, we examine the parameters that influence the accuracy of the measurement result and identify an optimal pattern design that yields the highest measurement accuracy. We compare the results with those that were obtained via GOBO projection of phase-shifted sinusoidal fringes. Finally, we experimentally verify the theoretical findings. We show that the proposed technique has several advantages over conventional fringe projection techniques, as the easy-to-build and cost-effective GOBO projector can provide a high radiant flux, allows high frame rates, and can be used over a wide spectral range.

Wetting transitions on patterned surfaces with diffuse interaction potentials embedded in a Young-Laplace formulation.

The Minimum Energy Paths (MEPs) of wetting transitions on pillared surfaces are computed with the Young-Laplace equation, augmented with a pressure term that accounts for liquid-solid interactions. The interactions are smoothed over a short range from the solid phase, therefore facilitating the numerical solution of problems concerning wetting on complex surface patterns. The patterns may include abrupt geometric features, e.g., arrays of rectangular pillars, where the application of the unmodified Young-Laplace is not practical. The MEPs are obtained by coupling the augmented Young-Laplace with the modified string method from which the energy barriers of wetting transitions are eventually extracted. We demonstrate the method on a wetting transition that is associated with the breakdown of superhydrophobic behavior, i.e., the transition from the Cassie-Baxter state to the Wenzel state, taking place on a superhydrophobic pillared surface. The computed energy barriers quantify the resistance of the system to these transitions and therefore, they can be used to evaluate superhydrophobic performance or provide guidelines for optimal pattern design.

Excimer laser micromachining of aspheric microlens arrays based on optimal contour mask design and laser dragging method

This paper presents an improved excimer laser micromachining method for fabricating arrayed microstructures with a predesigned surface profile. The proposed method is developed from a conventional biaxial laser dragging method, but numerical analysis and optimal pattern design on the contour mask are introduced so that the machined surface profiles can be well controlled and matched to the designed profiles. To demonstrate the capability of this new approach, an array of aspheric microlenses that have analog surfaces for minimizing the focal spot sizes of the lenses is designed and fabricated. An array of 10×10 microlenses with an aperture size of 100 μm and a designed aspheric profile are obtained experimentally. The machined surface profiles are closely matched to their designed ones, with a profile deviation of less than 1 μm. Furthermore, the machined surfaces are smooth, with an average surface roughness of around 2 nm. Optical measurements on these machined aspheric microlenses show minimized focal spot sizes approaching their optical diffraction limits.