The heart-on-a-chip is entirely 3D printed with built-in sensors that measure the contractile strength of the tissue, providing scientists with new possibilities for studying the musculature of the heart 

Technique paves the way for more complex, customizable devices

3D-printed heart-on-a-chip with integrated sensors

An array of silver-TPU ink sensors printed on a flexible TPU base. (Image courtesy of the Wyss Institute for Biologically Inspired Engineering)

New method combines precision printing of stretchable conductive inks with pick-and-place of electronic components to make flexible, wearable sensors

Low-cost wearables manufactured by hybrid 3D printing

Nature has produced exquisite composite materials&mdash;wood, bone, teeth, and shells, for example&mdash;that combine light weight and density with desirable mechanical properties such as stiffness, strength and damage tolerance.Since ancient civilizations first combined straw and mud to form bricks, people have fabricated engineered composites of increasing performance and complexity. But reproducing the exceptional mechanical properties and complex microstructures found in nature has been challenging.Now, a team of researchers at the&nbsp;<a href="http://seas.harvard.edu/" target="_blank">Harvard John A. Paulson School of Engineering and Applied Sciences</a> (SEAS) has demonstrated a novel 3D printing method that yields unprecedented control of the arrangement of short fibers embedded in polymer matrices. They used this additive manufacturing technique to program fiber orientation within epoxy composites in specified locations, enabling the creation of structural materials that are optimized for strength, stiffness, and damage tolerance.Their method, referred to as &ldquo;rotational 3D printing,&rdquo; could have broad ranging applications. Given the modular nature of their ink designs, many different filler and matrix combinations can be implemented to tailor electrical, optical, or thermal properties of the printed objects.&ldquo;Being able to locally control fiber orientation within engineered composites has been a grand challenge,&rdquo; said the study&rsquo;s senior author, <a href="https://www.seas.harvard.edu/directory/jalewis" target="_blank">Jennifer A. Lewis</a>, Hansjorg Wyss Professor of Biologically Inspired Engineering at Harvard SEAS. &ldquo;We can now pattern materials in a hierarchical manner, akin to the way that nature builds.&rdquo; Lewis is also a Core Faculty Member of the <a href="http://wyss.harvard.edu/" target="_blank">Wyss Institute for Biologically Inspired Engineering at Harvard.</a><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1569469293043-LewisNozzle.gif" style="width: 766px;" class="fr-fic fr-dib">The work, described in the journal&nbsp;<a href="http://www.pnas.org/" target="_blank">PNAS</a>, was carried out in the Lewis lab at Harvard. Collaborators included then-postdoctoral fellows Brett Compton (now Assistant Professor in Mechanical Engineering at the University of Tennessee, Knoxville), and Jordan Raney (now Assistant Professor of Mechanical Engineering and Applied Mechanics at the University of Pennsylvania); and visiting PhD student Jochen Mueller from Prof. Kristina Shea&rsquo;s lab at ETH Zurich.&nbsp;&ldquo;Rotational 3D printing can be used to achieve optimal, or near optimal, fiber arrangements at every location in the printed part, resulting in higher strength and stiffness with less material,&rdquo; Compton said. &ldquo;Rather than using magnetic or electric fields to orient fibers, we control the flow of the viscous ink itself to impart the desired fiber orientation.&rdquo;Compton noted that the team&rsquo;s nozzle concept could be used on any material extrusion printing method, from fused filament fabrication, to direct ink writing, to large-scale thermoplastic additive manufacturing, and with any filler material, from carbon and glass fibers to metallic or ceramic whiskers and platelets.The technique allows for the 3D printing of engineered materials that can be spatially programmed to achieve specific performance goals. For example, the orientation of the fibers can be locally optimized to increase the damage tolerance at locations that would be expected to undergo the highest stress during loading, hardening potential failure points.&ldquo;One of the exciting things about this work is that it offers a new avenue to produce complex microstructures, and to controllably vary the microstructure from region to region,&rdquo; Raney said. &ldquo;More control over structure means more control over the resulting properties, which vastly expands the design space that can be exploited to optimize properties further.&quot;&nbsp;&quot;Biological composite materials often have remarkable mechanical properties: high stiffness and strength per unit weight and high toughness. One of the outstanding challenges of designing engineering materials inspired by biological composites is control of fiber orientation at small length scales and at the local level,&rdquo; said Lorna J. Gibson, Professor of Materials Science and Engineering at MIT, who was not involved in the research. &ldquo;This remarkable paper from the Lewis group demonstrates a way of doing just that. This represents a huge leap forward in the design of bio-inspired composites.&quot;The <a href="http://otd.harvard.edu/" target="_blank">Harvard Office of Technology Development</a> has protected the intellectual property relating to this project.Previously, Lewis has conducted groundbreaking research in the 3D printing of&nbsp;<a href="http://www.seas.harvard.edu/news/2014/02/essential-step-toward-printing-living-tissues" target="_blank">tissue constructs with vasculature</a>,&nbsp;<a href="http://www.seas.harvard.edu/news/2013/06/printing-tiny-batteries" target="_blank">lithium-ion microbatteries</a>,&nbsp;and the first&nbsp;<a href="https://www.seas.harvard.edu/news/2016/08/first-autonomous-entirely-soft-robot" target="_blank">autonomous, entirely soft robot</a>.

A novel 3D printing method, called “rotational 3D printing,” yields unprecedented control of the arrangement of short fibers embedded in polymer matrices. Researchers used additive manufacturing technique to program fiber orientation within epoxy composites in specified locations, enabling the creation of structural materials that are optimized for strength, stiffness, and damage tolerance. (Video courtesy of the Lewis Lab/Harvard SEAS)

Arranging fibers just like nature does it

Novel 3D printing technique yields high-performance composites

Harvard researchers have developed a platform for creating soft robots with embedded sensors that can sense movement, pressure, touch, and temperature. (Image courtesy of Ryan L. Truby/Harvard University)

Soft robots that can sense touch, pressure, movement and temperature

Novel 3D printing method embeds sensing capabilities within robotic actuators

Most robots used in factories today are powerful but blind. They are programmed to do specific tasks repeatedly with high precision and speed, but until now have not been able to adapt to changes in the environment or handling variables. Robot arms often lack the ability to grasp an object if it is moved a few inches, not to mention picking or sorting millions of different products in a warehouse.As a result system integrators design shaker tables, feeders, conveyor belts, etc., so robots can be offered the same parts in the right orientation. Larger industrial robots need cages so they don’t accidentally hurt nearby people. Unlike human hands, which can perform tens of thousands of different tasks, robot arms can only be programmed for single tasks, and they need the proper end effectors.Additionally, most robots cannot sense, unless you equip them with force or vision sensors. They don’t know if tasks are performed properly, because they cannot see or feel.Traditional computer vision requires pre-registration of all objects, i.e. scanning and building computer-aided design (CAD) models for all items beforehand with expensive 3D cameras. The process is time-consuming and inflexible. Even if there was a box with exactly the same shape, but a different size, a robot couldn’t automatically recognize the differences and figure out how to grasp the new item.In addition, translucent packaging, reflective surfaces, and deformable objects (such as food and clothing) make robotic vision an even more difficult problem to solve. The additional non-robot hardware and integration end up costing four times more than a robot arm, which costs anywhere between $10,000 to $100,000.Adding intelligence to robotsTo solve these issues, deep reinforcement learning (DRL) is unleashing the full potential of robotics, giving them the ability to recognize and react to their surroundings and handle product variations. Robots can now learn from experiences with off-the-shelf cameras and deep neural networks.With enough data and practice, robots can now teach themselves new abilities, as was seen with robots’ ability to identify images and win video games. With every grasp and trial, a robot gets smarter and more adept at mastering the task. Furthermore, cloud-connected robots allow learnings to be shared with each other. This is a tremendous shift, making robotics solutions more dexterous, flexible, and scalable.Deep Learning (DL) is primarily used for image classification. Deep neural networks learn representations, rather than task-specific algorithms.Reinforcement learning (RL) is inspired by behavioral psychology. It learns control policies by trial-and-error through reward or punishment.Deep Reinforcement Learning (DRL) combines these two approaches. It is currently suited for:· Simple or simulated tasks· Fault-tolerant tasks· Just enough variation to make explicit modeling difficult· Easy-to-define goals (reward functions)· Semi-structured environmentsWarehouse as a testing ground for AIAutomation in warehouses is widely considered the “low-hanging fruit” for these technologies because tasks tend to be similar across warehouses, and the environment is more structured. For example, order picking represents more than 40% of operational costs across most warehouses. While tasks are repetitive, they involve some variation with products and packaging design, making it impossible to hard-program robots in advance.Furthermore, labor costs account for up to 70% of a warehouse’s total budget. Pressured by e-commerce companies such as Amazon, retailers are looking to automation to address labor shortages and reduce costs. Customer demand, price competition, and fast delivery requirements are driving a strong business case for warehouses to be the first adopter of AI-enabled robots.Chart: Why do we see AI-enabled robots in the warehouse first?<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNTY4OTAzMzQ5MzI3LTFfTDhkY3A1c1lfcEU0MTdqdW9VaEMwZy5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib"> Most tasks in a warehouse are fault tolerant, unlike tasks on a production floor or in the automotive industry. If a robot accidentally drops an object in a warehouse, it can try again as long as it achieves the required speed and success rates without damaging the goods.DRL is particularly suited for fault-tolerant simple tasks — actions a human can perform within a few seconds — with enough variation in semi-structured environments. As technology improves in environments like warehouses, it can then be applied in other industries, such as manufacturing, where tasks are more complicated and more uncertainties exist. Thus, an automated warehouse acts as an incubator, predicting a knowledge spill-over to many other market segments.Piece-picking is the holy grailWarehouse automation has been around for decades, in the form of automated storage, retrieval systems, and mobile robots like those from Kiva (now Amazon Robotics), that move items around.But most of the pick-and-pack operations within a warehouse are still performed by humans, with labor costs accounting for 50 to 70% of the overall warehouse budget. Worker shortages have driven up salaries by a rate of 6 to 8% every year, while robot costs have fallen considerably since the 1990s.Piece-picking has long been the holy grail of robotics. Year after year, incumbents such as Amazon and KUKA host robotics challenges for startups and academic teams to create machines that can identify, pick up and stow goods. The emergence of deep learning allows robots to recognize, pick, and place hundreds or up to thousands of items.But the technology is not yet perfect. It’s still challenging for a machine to recognize tens of millions of objects, and manipulate deformable objects or items with transparent packages. However, our interviews with Locus Robotics and Osaro indicate that many industry experts expect the technology will mature. In addition, we will have a robot vision camera that can recognize almost everything in a warehouse within five years. If that happens, it will affect not just warehouses, but retail, delivery, and many other applications that we haven’t yet imagined.Pushing towards standard modelsTechnology improvements in warehouse automation and beyond will also push the mature, but fragmented, robotics industry to become more standardized and modular. Given the nature of narrow AI, most Silicon Valley startups in the AI-enabled robotics industry choose to focus on specific vertical applications and collect proprietary data as a defensive advantage.Piece-picking by robots is the best example. As the technology improves, we will see warehouse piece-picking startups enter manufacturing, food, and agriculture markets. Moving away from manually programming a robot and having it learn and act autonomously on specific simple tasks — and sharing the learning — will become more important in the future.However, it’s not easy to find scalable and technically feasible business cases like piece picking that customers are willing to pay for. For example, assembly tasks vary from factory to factory, making it difficult to get sufficient training data or scale a solution across different customers.Given current technology constraints, there’s still a trade-off between precision and flexibility. Deep learning allows robots to handle variation, but these AI-enabled robots still cannot achieve the same precision and accuracy as traditional robots, at least not today.Some startups are providing modules or technology stacks for other players in the ecosystem to mitigate the complexity and scalability issues mentioned above. New areas where startups are likely to enter and disrupt include teleoperation modules, controllers that allow for safer human-robot collaboration, human-centered AI protocols, and sensors that can quantify human behavior.Eventually, we may see unified operating systems for AI-enabled robots similar to Windows or Android in the consumer electronics space, or standard user interfaces that will fundamentally transform the fragmented robotics industry and further accelerate its disruption.Standard modules and interfaces will bring down the cost to enter the market and shorten the time to market. As DRL and robotics technology improves, we will see a boom across industries including agriculture, food processing, home, and even surgical robotics.How technology will transform the industry landscapeLed by industry leaders like Amazon and Ocado, a British online grocery store, retailers see efficient and cost-effective supply chains as a key to success and are incentivized to automate their warehouses for lower cost, lower management complexity, and higher scalability. While Amazon keeps its Kiva mobile robots and automated warehouse solutions for in-house use only, Ocado launched its fulfillment platform to help other companies store, pick, and transport groceries. But most retailers still rely on material-handling companies and system integrators to build and maintain an automated warehouse.Incumbent material-handling companies tend to exploit the current technology, focusing on high-revenue-potential retrofit projects. This gives startups an opportunity to enter from the lower-end markets, where incumbents are less interested, and thus would not respond immediately. Dozens of startups offer scalable and affordable solutions that address customer needs for robots that can handle high-variability, low-precision tasks, such as piece picking in the warehouses.On the other hand, large robotics companies have long focused on developing high-speed and more-precise solutions to serve their main customers in the automotive and manufacturing industries. The pursuit of absolute precision is contrary to the process of deep learning, where results improve over time through trial and error.Some robotics companies saw an opportunity to enter new segments that require robots to handle high-variability, but lower-precision tasks, and began to build in-house AI teams and explore partnerships with startups developing deep neural network solutions for robots.There are currently more than 20 warehouse piece-picking robot startups worldwide, including Osaro and Righthand Robotics. Most of these startups (between seed round and Series C funding) are working on pilot projects with incumbent material-handling, retail, and robotics companies.Software and services will also capture more values, while premiums in hardware will decrease. With this power shift, as well as potential mergers and acquisitions, the landscape will change significantly over the next few years.The future of AI-enabled roboticsThoughts vary on the effect that AI and DRL will have on the robotics industry. One scenario is the robotics industry will consolidate because of the AI network effect, which says results improve as the amount of training data they’re given increases. This idea is that whoever owns the most proprietary data will win the competition.However, new researches in the areas of Transfer Learning, Meta Learning, and Zero-Shot Learning make it possible to learn from fewer and fewer examples, generalizing learning results across different fields. Cloud-based AI and robotics will also help accelerate learning and diffusion.As these technologies evolve, the landscape may face yet another significant change. This all starts from the warehouse!

The impact of artificial intelligence within warehouses will act as a crystal ball for AI, robotics in other industries

Why is Warehouse Automation So Important for AI Professionals?

<h1>Introduction</h1>3D printing technologies based on <a href="https://www.wevolver.com/article/digital.light.processing.3d.printing.explained" rel="noopener noreferrer" target="_blank">DLP printing (Digital Light Processing)</a> are frequently used for fabricating complex objects without tooling and machining. DLP printing involves the light-mediated conversion of a liquid resin containing monomer or oligomer photopolymers to a solid object. This process leverages the versatility of polymer chemistry to make complex objects with programmable optical, chemical or mechanical properties. Versatility underpins the popularity of polymer materials within the 3D printing community, encouraging research in photopolymer chemistry and printing applications. <iframe src="https://www.youtube.com/embed/97ARLiTHjX0?&wmode=opaque&enablejsapi=1&origin=https://www.wevolver.com" allowfullscreen="" class="fr-draggable" style="width: 788px; height: 500px;" frameborder="0" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>This video explains the process and working of DLP printers in detail - by Professor Bill Hammack, Department of Chemical Engineering, University of Illinois Despite the growing enthusiasm for 3D printing in rapid prototyping applications, implementation in manufacturing environments to produce end-use parts has lagged. Common problems include setting and maintaining minimum specifications, specifically those related to material durability and weathering. Additive manufacturing methods rely on tight synchronicity between hardware, software and chemistry to achieve reproducibility at scale. This article highlights the role of polymerization in the co-development and simultaneous tuning of each component in the DLP process. By understanding the fundamentals of polymerization, developers can simultaneously tune process components, avoiding common pitfalls contributing to part defects, detachment, post-processing and weathering problems.This article is sponsored by polySpectra, which makes functional materials for advanced additive manufacturing. PolySpectra CEO Raymond Weitekamp explained to Wevolver that they&#39;ve spent thousands of hours and hundreds of thousands of dollars characterizing the thermomechanical properties of dozens of additive manufacturing polymers. For Wevolver readers they are providing a free specification sheet of their newest materials at&nbsp;<a href="http://www.polyspectra.com/wevolver" rel="noopener noreferrer" target="_blank">www.polyspectra.com/wevolver</a> <h1>Photopolymerization: A multi-stage, dynamic process</h1>A photopolymer is a polymer whose properties alter upon exposure to light. Photopolymers are a liquid mixture containing monomers and oligomers, which can be manipulated to achieve specified physical properties. The process of photopolymerization (also known as photocuring or photo crosslinking) describes the crosslinking of monomers / oligomers within the liquid resin to form a network polymer. This process typically occurs via cationic or radical mechanisms and is mediated by the addition of photoinitiators. Photoinitiators are molecules that convert photolytic energy into reactive species to activate polymerization through specific functional groups.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNTY4Mjk2NjE4NDExLVBob3RvLXBvbHltZXJfc2NoZW1lMSAwMi5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 550px;" class="fr-fic fr-dib">Photopolymerization is an attractive method of curing polymers for 3D printing applications because it can be performed selectively. However, the process of photopolymerization is complex and sensitive to a range of parameters including wavelength, temperature and moisture. The extent and homogeneity of the polymerized cross-linked network is an important determinant in the properties of the final hardened material. Photopolymerization is a multi-stage and dynamic process. <a href="http://rawwerks.com/sla-utility/" rel="noopener noreferrer" target="_blank">Photopolymerization kinetics</a> is described as a &ldquo;working curve&rdquo;, mapping cure depth (depth to which light induces polymer crosslinking) as a function of light exposure at different wavelengths. Critical exposure (Y-intercept on the working curve) is defined as the minimum light exposure required for the onset of curing. The behaviour of the photopolymer under specified light exposure conditions (wavelength, power, exposure time and velocity) affect the printing process. There are a wide range of photopolymers available, responding to wavelengths in the UV (190-400 nm), visible (400-700 nm) and IR ranges (700-1000 nm). Light of different wavelengths penetrate materials to different cure depths. <img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNTY4Mjk4MzAwNTYzLVBSLTQ4LVdDLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=">An example of a Working Curved that shows the relation between UV light dose and curing depth of the resin. Image courtesy Polyspectra. <iframe src="https://www.youtube.com/embed/Lw3BY2_yGVU?&wmode=opaque&enablejsapi=1&origin=https://www.wevolver.com" allowfullscreen="" class="fr-draggable" style="width: 788px; height: 470px;" frameborder="0" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>This video explains how the working curve impacts the 3D print and how to find the correct settings - by Autodesk Ember <h1>Photopolymerization: A fundamental process in DLP printing</h1>The dynamic nature of photopolymerization suggests that it is a non-binary process. In DLP printing, light is projected into the polymer resin forming a 2D image. This simultaneously exposes all the designated regions within a polymer layer. The overall printing time is reduced through compared to rastered stereolithography, due to the parallelization of the photocuring process. The projected 2D image is composed of pixels, which become voxels when translated into three dimensions. This has led to the misconception that DLP is an essentially digital binary processtechnology and that print resolution is purely a function of printer hardwarethe DLP optics. In reality, voxels contain photopolymers that are fluxing between stages of the photopolymerization process: going from liquid to their gel point and then on towards their full cross-linking density.<iframe src="https://www.youtube.com/embed/5qTAmPrHLow?&wmode=opaque&enablejsapi=1&origin=https://www.wevolver.com" allowfullscreen="" class="fr-draggable" style="width: 788px; height: 470px;" frameborder="0" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>This video shows the impact of voxels on the 3D print and how printers can actually achieve resolutions smaller than the nominal resolution of the DLP projector - by Autodesk Ember. This can influence the 3D printing process in several ways. Firstly, printing speed should be calibrated to account for photopolymerization kinetics. If not, voxels may expand beyond their digitally defined physical space, reducing feature resolution of the finished part. Further, photopolymerization may cause shrinkage in the hardened polymer. Shrinkage coupled with cycles of thermal expansion and contraction experienced during the printing process may induce stressinduces stresses on the part, . These stresseswhich can manifest in warping or layer splitting or separation in the finished object. Strategies to mitigate these effects include tuning both software and hardware to select appropriate exposure protocols (velocity and speed) and control environmental influences (temperature and humidity). Finally, the cure depth is an important parameter to consider when implementing a DLP printing protocol. Cure depth directly impacts the z- axis settings of the printer. It may also influence the selection of printing parameters such as print velocity.Recommended reading:&nbsp;<a href="https://www.wevolver.com/article/digital.light.processing.3d.printing.explained" rel="noopener noreferrer" target="_blank">Digital Light Processing 3D printing explained</a><h1>Detachment: Building and breaking interactions between materials and hardware</h1>3D objects are rendered through the sequential hardening of photopolymer layers onto a substrate (known as a build plate). An essential step in any 3D printing process is the detachment of the finished part from the substrate. This step can prove problematic, as the printing process can induce suction forces, securing the part to the substrate. Numerous separation mechanics have been described to overcome these suction forces. Examples include tilting the resin tray and peeling the part off or using a sliding mechanism. Building the part on a flexible window, to which pressure may be applied to break suction forces is also a common method.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNTY4MzU3NDgwMzU4LUNhcmJvbiBCZWQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==">A print (with support structure) attached to a print bed after printing. Source: Carbon 3DBuilding an oxygen permeable window within the substrate allows oxygen to access the photopolymer directly in contact with the substrate. This creates a depletion zone of inactive resin which does not adhere to the substrate, facilitating part removal. However, this method is only suitable for photopolymers which are quenched by oxygen, such as acrylates and methacrylates. An alternative strategy is to modify the viscosity of the liquid photopolymer resin. Low viscosity solutions enable higher printing speeds and concomitant reduction in the suction forces adhering the part to the substrate. This highlights an important aspect of 3D printing; the relationship between the photopolymer materials and the design of the printer hardware. It is widely recognised that surface adhesion is important to provide a foundation for the object to build upon. Consequently, the materials within the hardware and the finished printed object should be compatible.<h1>Post-processing: The significance of photopolymerization in scaling production</h1>DLP printing found initial application as an instrument for rapid prototyping in research settings. Introducing DLP printing into manufacturing settings has been slower due to problems with scaling production, reproducibility and part quality. The co-development of printing processes and materials is not only critical during the initial build process. Photopolymerization kinetics also affect post-processing of end-use parts. The acceptance of 3D printing into manufacturing settings has been restricted by extensive post-processing requirements including:<ul><li>Removal of the support structure (onto which the part is fabricated).</li><li>Part cleaning to remove debris and residual materials.</li><li>Post-curing (usually thermal or optical) to completely harden certain materials.</li><li>Part finishing (such as sanding, painting or varnishing) to remove the &ldquo;boxy&rdquo; surface finish characteristic of DLP printing.</li></ul><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNTY4MzU3NTQ3NzY2LXBvc3QgcHJvY2Vzc2luZy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">Rinsing off resing, removing support, and curing with UV light. Source: FormlabsPost-processing steps are often performed in small batches under carefully controlled conditions. These processes can be difficult to automate, adding substantial time and cost to the production process. Advances in automation are ongoing, with some companies utilising robotics to automate assembly lines integrating 3D printers with post-processing equipment. Advances in printing hardware and software enabling automated monitoring could enable DLP printing at scale. However, the widespread implementation of automated processing lines has yet to be realised. Post-processing requirements are heavily dependent on photopolymer characteristics, with some materials requiring more extensive modification than others. Strategies to streamline operations should include selecting materials with limited post-processing requirements yet withstand weathering processes to maintain durability.<h1>Conclusion</h1>The combination of pivotal developments in 3D printing hardware, software and materials has paved the way towards the implementation in prototyping and manufacturing. With an increased awareness of the importance of co-developing each component simultaneously, the development of new applications for 3D printing of end-use parts is slowly becoming a reality. The relevance of DLP printing in the manufacturing sector will depend heavily on the ability to cost-effectively produce end-parts that are durable. The dynamic nature of photopolymerization continues throughout the lifetime of a part. The weatherability of hardened polymers is an important determinant of part durability, specifically the ability to maintain toughness and impact strength over time. By understanding the kinetics of photopolymerization and thermodynamic properties of the resulting polymer networks, developers can select materials to mitigate common problems, yet maintain desired properties throughout the lifetime of a part. <hr>This article was sponsored by&nbsp;<a href="http://polyspectra.com/wevolver" rel="noopener noreferrer" target="_blank">polySpectra</a>. polySpectra makes functional materials for advanced additive manufacturing in Berkeley, California, USA. They use light-activated catalysts to 3D print advanced functional materials. Polyspectra&#39;s platform enables them to deliver materials with a broad spectrum of tailored properties from a single chemical system.For Wevolver readers polySpectra is providing a free specification sheet of their newest materials at&nbsp;<a href="http://www.polyspectra.com/wevolver" rel="noopener noreferrer" target="_blank">www.polyspectra.com/wevolver</a>

DLP (Digital Light Processing) 3D printing uses photopolymerization to create 3D objects. Understanding the photopolymerization process can help you mitigate common problems that make your prints fail or that reduce print quality.

DLP 3D Printing: Understanding process and materials enables you to prevent production problems

Additive manufacturing, otherwise known as 3D printing, can be used to manufacture porous electrodes for lithium-ion batteries&mdash;but because of the nature of the manufacturing process, the design of these 3D printed electrodes is limited to just a few possible architectures. Until now, the internal geometry that produced the best porous electrodes through additive manufacturing was what&rsquo;s known as an interdigitated geometry&mdash;metal prongs interlocked like the fingers of two clasped hands, with the lithium shuttling between the two sides.Lithium-ion battery capacity can be vastly improved if, on the microscale, their electrodes have pores and channels. An interdigitated geometry, though it does allow lithium to transport through the battery efficiently during charging and discharging, is not optimal.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1568214668191-0730-em-rahul-battery.png" style="width: 766px;" class="fr-fic fr-dib">Lattice architecture can provide channels for effective transportation of electrolyte inside the volume of material, while for the cube electrode, most of the material will not be exposed to the electrolyte.Rahul Panat, an associate professor of mechanical engineering at Carnegie Mellon University, and a team of researchers from Carnegie Mellon in collaboration with Jonghyun Park, assistant professor of mechanical and aerospace engineering at Missouri S&amp;T have developed a revolutionary new method of 3D printing battery electrodes that creates a 3D microlattice structure with controlled porosity. 3D printing this microlattice structure, the researchers show in a paper <a href="https://www.sciencedirect.com/science/article/pii/S2214860418302379#bib0095" rel="noopener" target="_blank">published in the journal Additive Manufacturing</a>, vastly improves the capacity and charge-discharge rates for lithium-ion batteries.&ldquo;In the case of lithium-ion batteries, the electrodes with porous architectures can lead to higher charge capacities,&rdquo; says Panat. &ldquo;This is because such architectures allow the lithium to penetrate through the electrode volume leading to very high electrode utilization, and thereby higher energy storage capacity. In normal batteries, 30-50% of the total electrode volume is unutilized. Our method overcomes this issue by using 3D printing where we create a microlattice electrode architecture that allows the efficient transport of lithium through the entire electrode, which also increases the battery charging rates.&rdquo;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1568214704238-Screenshot_2019-09-11+3D+printing+the+next+generation+of+batteries.png" style="width: 766px;" class="fr-fic fr-dib"> The additive manufacturing method presented in Panat and Park&rsquo;s paper represents a major advance in printing complex geometries for 3D battery architectures, as well as an important step toward geometrically optimizing 3D configurations for electrochemical energy storage. The researchers estimate that this technology will be ready to translate to industrial applications in about two to three years.The microlattice structure (Ag) used as lithium-ion batteries&rsquo; electrodes was shown to improve battery performance in several ways such as a fourfold increase in specific capacity and a twofold increase in areal capacity when compared to a solid block (Ag) electrode. Furthermore, the electrodes retained their complex 3D lattice structures after forty electrochemical cycles demonstrating their mechanical robustness. The batteries can thus have high capacity for the same weight or alternately, for the same capacity, a vastly reduced weight, which is an important attribute for transportation applications.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1568214728313-0730-em-rahul-battery-microscope.png" style="width: 766px;" class="fr-fic fr-dib">SEM images of 3D printed electrodes for Li-ion batteries used for electrochemical cycling in the researchers&rsquo; study. Image taken from top of microlattice electrodes with height of about 250mm.The Carnegie Mellon researchers developed their own 3D printing method to create the porous microlattice architectures while leveraging the existing capabilities of an Aerosol Jet 3D printing system. The Aerosol Jet system also allows the researchers to print planar sensors and other electronics on a micro-scale, which was deployed at Carnegie Mellon University&rsquo;s College of Engineering earlier this year. This novel 3-D printing method could be applied to battery technology with a collaboration with the Missouri university, where researchers developed 3-D battery design and analysis, cell fabrication technology, and electrochemical analysis via simulation and modeling.Until now, 3D printed battery efforts were limited to extrusion-based printing, where a wire of material is extruded from a nozzle, creating continuous structures. Interdigitated structures were possible using this method. With the method developed in Panat&rsquo;s lab, the researchers are able to 3D print the battery electrodes by rapidly assembling individual droplets one-by-one into three-dimensional structures. The resulting structures have complex geometries impossible to fabricate using typical extrusion methods.&ldquo;Because these droplets are separated from each other, we can create these new complex geometries,&rdquo; says Panat. &ldquo;If this was a single stream of material, as in the case of extrusion printing, we wouldn&rsquo;t be able to make them. This is a new thing. I don&rsquo;t believe anybody until now has used 3D printing to create these kinds of complex structures.&rdquo;This revolutionary method will be very important for consumer electronics, the medical devices industry, as well as aerospace applications. This research will integrate well with the biomedical electronic devices, where miniaturized batteries are required. Non-biological electronic micro-devices will also benefit from this work. And on a bigger scale, electronic devices, small drones, and aerospace applications themselves can use this technology as well, due to the low weight and high capacity of the batteries printed using this method.The team, which also includes mechanical engineering Ph.D. student Mohammad Sadeq Saleh and postdoctoral researcher Jie Li at Missouri S&amp;T, is also working on creating more complex three-dimensional structures, which can simultaneously be used as structural materials and as functional materials. For example, a part of a drone can act as a wing, a structural material, while simultaneously acting as a functional material such as a battery.

A new method of fabricating battery electrodes using Aerosol Jet 3D printing.

3D printing the next generation of batteries

What is DLP is a 3D printing? This article aims to provide an in-depth understanding of DLP 3D printing, its working principles, advantages, limitations, and diverse applications in various sectors.

DLP 3D Printing: Exploring Technology, Challenges, and Applications

One key element of the future production landscape is highly flexible Human-Robot Collaboration (HRC). This article describes 3 case studies which illustrate how collaborative robots change the way people will manufacture. KUKA, one of the world&#39;s largest suppliers of industrial robots, has written a free, downloadable white paper called &quot;<a href="http://bit.ly/kuka-whitepaper-US" rel="noopener noreferrer" target="_blank">Shaping future production landscapes</a>.&quot; The white paper describes &#39;megatrends&#39; that impact manufacturing and 3 key factors to designing production infrastructures that can meet the requirements of the future.&nbsp;<hr><h1>Intro</h1><h2>Human-robot collaboration&nbsp;</h2>In human-robot collaboration, the robot assists the human operator. This means: The machine does not replace the human, but complements his capabilities and relieves him of arduous tasks. These can include overhead work, for example, or the lifting of heavy loads. Autonomous, collaborative robots are also used to supply production workstations.In the ideal &#39;factory of the future&#39; there is no separation between automated and manual workstations. Humans and robots collaborate optimally &ndash; without separation and without safety fencing.<h2>Human-robot collaboration: the advantages</h2>HRC-capable robots (often labeled &#39;Collaborative Robots&#39; or &#39;Cobots&#39;) are rendered mobile and capable of performing different tasks flexibly using mobile platforms. They can thus be individually deployed at whatever location and for whatever purpose corresponds to production requirements &ndash; dependent on the required batch size, for example. Furthermore, these types of robots offer maximum flexibility by means of so-called spontaneous automation: They support a user as an assistant in the case of workload peaks and resource bottlenecks in production operations.Human-robot collaboration changes industrial production and manufacturing and can bring a number of advantages over traditional automation or manual labor:<ul><li>Increased flexibility in production</li><li>Relief of employees by performing ergonomically unfavorable work steps that could not previously be automated</li><li>Reduced risk of injuries and infections</li><li>High-quality performance of reproducible processes &ndash; without requiring type-specific or component-relevant investment.</li><li>Increased productivity and improved system complexity thanks to integrated sensors</li></ul> <h1>HRC Case Studies</h1>To give you an idea of the impact of collaborative robots in the workspace we&#39;ve gathered 3 case studies to show you the impact of these robots and the challenges they overcome. <h2>Case Study 1: Lightweight robots supporting operators in adhesive bonding processes.</h2><h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1566292124494-KUKA+LBR+iiwa+Duerr.jpg" class="fr-fic fr-dib" style="width: 766px;"></h2>All images courtesy KUKASystem and machine builder <a href="https://www.durr.com/en/" rel="noopener noreferrer" target="_blank">D&uuml;rr</a> uses two sensitive LBR iiwa robots in final assembly. Without a safety fence, they perform key tasks in the application of adhesive beads. This improves quality, saves time and lowers unit costs.<div data-ignore="true">At the company, humans and robots work together in final assembly without the need for physical safeguards. Sensitive lightweight robots are used for the adhesive bonding of GPS antenna covers and tanks in the vehicle body. The solutions improve the quality of the adhesive bonding result, save time and lower unit costs.&nbsp;</div>The LBR iiwa detects any fault that arises when the GPS antenna cover is loadedFor application of adhesive to the GPS antenna cover, the assembly worker places the workpiece into the robot gripper manually. The gripper sucks onto it and moves it to the adhesive nozzle on the application tower. The robot slowly moves the GPS antenna cover upwards to the application nozzle. If it encounters an obstacle, it moves back a little thanks to its collision detection ability and starts the motion over from the beginning. Only after three attempts does it move back into the starting position. Otherwise, the adhesive application process starts and the adhesive bead is applied carefully while the robot executes the path. Finally, back at the starting point, the assembly worker removes the GPS antenna cover and mounts it on the vehicle. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;&nbsp;<iframe src="https://www.youtube.com/embed/PdAXCNtXabc?&wmode=opaque" allowfullscreen="" class="fr-draggable" style="width: 767px; height: 429px;" frameborder="0"></iframe>Precise adhesive beads thanks to the seventh axis of the LBR iiwaFor the automated process of gluing the tank into place in final assembly, the skilled worker guides the tank to a turntable with the aid of a manipulator. There he cleans it, moves it into the correct position and transfers it directly to the robot for further processing. When the starting point is reached on the stationary tank, the nozzle opens under pressure so that no air bubbles are created. The robot then applies the adhesive bead onto the tank very evenly. Sensors on the application head monitor the accurate height of the bead. Thanks to its seventh rotating axis, the robot glues in a radius of 360 degrees &ndash; without re-orienting or having to interrupt the bead. As soon as the robot has completed its task, the skilled worker fits the tank into the vehicle body at the specified position.<a href="http://www.durr.com/" target="_blank">D&uuml;rr</a> has already sold ten systems in the field of adhesive bonding, and is working on HRC solutions for the robot-based adhesive bonding of small washers and other components. <h2>Case Study 2: Human-robot collaboration during the adjustment of headlights.</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1566292345359-Fahrassistenzsystemprfstnden_Drr.jpg" style="width: 766px;" class="fr-fic fr-dib">To reduce the strain on the workers, two KUKA LBR iiwa cobots perform the unergonomic task of adjusting fog lights at Ford. Parallel to this, human colleagues can adjust the main headlights.<article data-ignore="true">The initial situationIn the automotive industry, vehicle fog lights have previously been adjusted manually by human operators. While stooped over, the human operator searches for the hard-to-reach opening for the adjusting screws in the bumper area. Once he has found the adjusting screw, he positions the tool on it extremely carefully without damaging the adjustment opening on the bumper.</article><article data-ignore="true">The solutionTo provide relief for the human worker during this ergonomically unfavorable work and simultaneously achieve improved of the adjustment, Ford VOME (Vehicle Operation Manufacturing Engineering), D&uuml;rr Assembly Products and KUKA have jointly developed an innovative alternative concept for the conventional process as part of a feasibility study. The solution called for the use of the KUKA LBR iiwa cobot. The sensitive robot adjusts the fog lights fully automatically. In doing so, humans and robots work on the same vehicle without additional safety equipment.</article><iframe src="https://www.youtube.com/embed/9HWY-CLR3Co?&wmode=opaque" allowfullscreen="" class="fr-draggable" style="width: 766px; height: 419px;" frameborder="0"></iframe>TeamworkWhile the human operator adjusts the conventional headlights, the cobot adjusts the hard-to-reach fog lights. Two lightweight robots are already in use in four headlight/driver assistance system test stands for the new Ford Focus C519 at the Ford plant in Saarlouis. &nbsp; &nbsp; &nbsp; &nbsp;The secret of the HRC conceptWith its size and joint torque sensors, the robot detects contact immediately and reduces its level of force and speed instantly. These characteristics make it possible to work with human operators in confined spaces. Furthermore, with its high-performance servo control, the cobot detects contours quickly under force control. In combination with an end effector specially developed by D&uuml;rr (consisting of a camera system and an adjustment screwdriver), the robot positions the adjustment screwdriver according to the hole coordinates acquired by the camera system. The adjusting screw itself is located approximately 80 mm behind the hole in the bumper. Thanks to sensitive movements, the cobot optimally positions the adjustment tool into the screw head.Redundant safety is provided by the HRC-capable, heavy-duty aluminum gantry from D&uuml;rr Assembly Products &ndash; on which the KUKA LBR iiwa is positioned in a ride-on installation above the light collecting box directly in front of the headlight to be adjusted. The advantage here: additional robot positioning can be dispensed with. <h2>Case Study 3: Using a cobot to install pump wells. </h2><h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1566292578317-KUKAflexFellow_Platzierung_im_Arbeitsbereich_IMG_3628.jpg" style="width: 766px;" class="fr-fic fr-dib"></h2>In the future, BSH Hausger&auml;te GmbH will be using a <a href="https://www.kuka.com/en-us/products/mobility/mobile-robot-systems/kuka-flexfellow" rel="noopener noreferrer" target="_blank">KUKA flexFELLOW</a> to carry out the installation of pump wells on the dishwasher production line.&nbsp;<article data-ignore="true">The initial situationThe <a href="https://www.bsh-group.com/us/" rel="noopener noreferrer" target="_blank">BSH Hausger&auml;te</a> GmbH factory in Dillingen, Germany is Europe&rsquo;s largest and most modern factory for dishwashers. Around 10,000 machines leave the production line every day in two-shift operation. There are a total of seven production lines for manufacturing dishwashers.Screw fastening of the pump covers in the dishwasher is an ergonomically inconvenient task as the employee has to lean into the dishwasher housing to perform the task. The mechanical assistant now takes on this monotonous step in the process.&nbsp;The task &nbsp; &nbsp;&nbsp;&nbsp; &nbsp;Its contribution has already been tested successfully over several months as part of a pilot system. In addition to relieving the human operator of a cumbersome task, the robot also contributes by documenting its work and indicating whether the screws have been tightened correctly or not.The solution &nbsp; &nbsp; &nbsp; &nbsp;The key challenge when designing the system was to ensure that the manual workstation remained unchanged and that the automation solution could be integrated into the existing assembly line. Its sensitive and responsive capabilities enable it to recognize if, for example, a pump well component is not positioned correctly and then presses it into place.&nbsp;<iframe src="https://www.youtube.com/embed/jtkJQJXO7AQ?&wmode=opaque" allowfullscreen="" class="fr-draggable" style="width: 767px; height: 413px;" frameborder="0"></iframe>The advantages of using a cobot:<ul><li>Reduction of the manual workload in an ergonomically inconvenient task</li><li>Automated documentation of work steps</li><li>Indication of correct screw fastening operation</li></ul>Using its responsive capabilities, the cobot can then calibrate itself independently at its workstation, use a search run mode to find the screw positions, re-apply pressure to the component if it is not correctly positioned and finally tighten the four screws. <hr><h1> </h1><h1>Further Reading</h1><ul><li>Specifications of the <a href="https://www.wevolver.com/wevolver.staff/kuka.lbr.iiwa/" rel="noopener noreferrer" target="_blank">KUKA LBR iiwa</a></li><li>&quot;<a href="http://bit.ly/kuka-future" rel="noopener noreferrer" target="_blank"></a><a href="http://bit.ly/kuka-whitepaper-US" rel="noopener noreferrer" target="_blank">Shaping future production landscapes,</a>&quot; KUKA&#39;s white paper describing the &#39;megatrends&#39; that impact manufacturing and 3 key factors (people, technology and adaptation) to designing production infrastructures that can meet the requirements of the future.</li></ul> </article>

In human-robot collaboration, human and machine work hand in hand. The human operator controls and monitors production, the robots perform the physically strenuous work. Both contribute their specific capabilities.

Human-robot collaboration: 3 Case Studies

This article is part of a series about the usage of robots in harsh environments, written by post-doctoral robotics researcher Matthew Nancekievill. Find the second article, on subsea environments,&nbsp;<a href="https://www.wevolver.com/article/robotics.for.harsh.environments.subsea" rel="noopener noreferrer" target="_blank">here.</a><hr>Lets face it, there are some jobs that we just don&rsquo;t want to do, or CAN&rsquo;T do that we will have to get robotic platforms to complete. This is especially true of harsh environments such as subsea, mining, space, arctic, often forgotten surgical robotics and nuclear decommissioning. In this article we are going to take a brief look at robotic platforms currently deployed within the nuclear industry, why they&rsquo;re required and solutions that are still required for all you innovators out there. &nbsp;With decommissioning costing the UK &pound;3billion/yr and estimated costs of &pound;121 billion over the next 120 years, there is a requirement for increased efficiencies and decommissioning rates that robotics can provide.&nbsp;Hopefully this article acts as a summary of robotic solutions in nuclear decommissioning without being too much of an exhaustive list.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNTU5NjY4MDk3MDA3LUltYWdlIDIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib"><h1>A look at the Nuclear Decommissioning Environment</h1>Decommissioning happens around us all the time, old buildings get torn down, coal power plants shutdown and vehicles get scrapped. The nuclear industry is no different with the reactors, storage facilities and processing elements all requiring decommissioning when they reach the end of their useful life.Hazardous substances can be found in all the above environments with asbestos, chemicals used during refinement, rare earth metals and oils that can&rsquo;t be put into our main waste stream all examples of hazardous substances. The Nuclear industry faces all the same problems but adds one to the list, &ldquo;nuclear waste&rdquo;.I&rsquo;ve always felt that nuclear gets a bad rap in the press, with all the pollutants and oil spills throughout the years created from coal power plants seemingly ignored when nuclear waste is mentioned. However, the effects of nuclear radiation on the body can be very unforgiving.To give you a flavour, researchers working with weak radioactive sources, such as myself, are allowed a total yearly dose of &lt;1 mSv attributed to radiation work, registered radiation workers in the UK &lt;20 mSv. This is a large safety factor to account for medically proven effects of radiation at radiation levels &gt;250 mSv with 1,000 mSv likely to kill you within a few days to a couple of weeks. (Average background radiation dose in the UK is approximately 2.7 mSv)Compare this to radiation doses in some of the most radioactive places on earth, such as the UK&rsquo;s Sellafield Site or the Fukushima accident, where in the most extreme cases (no really, the most extreme cases, the majority is not like this) dose-rates of around 10,000 mSv.h-1 are possible (check-out <a href="http://irid.or.jp/en/research/20150420-2/" rel="noopener noreferrer" target="_blank">these survey results</a> from the IRID and the shape-changing robot mentioned later.This is before you add in the difficulties of the physically constrained and tight working spaces, high temperatures, contaminated water used for cooling and, in the case of nuclear accidents such as Fukushima, an unknown physical layout &ldquo;behind the door&rdquo; due to explosions within the reactor buildings.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNTU5NjcyODIxNzYyLUZ1a3UuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib"><h1>Current Practices</h1>In less radiologically extreme environments, much of the work is carried out by human workers in air-fed suits with multiple layers of gloves, some of which could be lead-lined (lead-lined gloves) worn to avoid contamination and puncturing of the suit on sharp edges. This often means that with all the getting ready, decontamination at the end of the shift and the physical exertion required to operate in these suits, an 8-hour work shift could result in anywhere between 15 minutes to 2 hours of actual decommissioning with power tools cumbersome to use and movement awkward. Workers have been known to empty their boots at the end of their shift of all their sweat that has built up&hellip; Workers are, at the root of it, tasked with dismantling the facility. This means cleaning, chopping and moving all sorts of materials into the correct waste stream and then moving on to the next object or structure.<h2>Robotics in Nuclear</h2>It is clear that some of these repetitive tasks or highly radioactive areas lend themselves to the use of robotic platforms. There has been a large body of work conducted on developing solutions for just that. Aquatic robotic platforms for use within submerged nuclear waste storage tanks, robotic manipulators for laser cutting of structures, drone-based devices for site surveys and ground-based robots for automated warehouse characterisation and unknown environments.Examples of these are:The Forth AVEXIS, developed jointly by Forth Engineering and the University of Manchester. A submersible ROV designed to be deployed within the Magnox Swarf Storage Silo and fit through a 6&rdquo; access port. More information within the video.<iframe src="https://www.youtube.com/embed/OLvAQFz5wh8?&wmode=opaque&enablejsapi=1&origin=https://www.wevolver.com" allowfullscreen="" class="fr-draggable" style="width: 766px; height: 443px;" frameborder="0" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-gtm-yt-inspected-7="true" id="626921597" title="Avexis ROV"></iframe>The LaserSnake2, which combines a multi-jointed &ldquo;snake-arm&rdquo; manipulator with a powerful laser-cutter. Developed by OCRobotics, The Welding Institute, National Nuclear Laboratory, Laser Optical Engineering Ltd. And ULO Optics. It is designed to cut and reduce the size of objects and structures to fit in dedicated waste containers.<iframe src="https://www.youtube.com/embed/hqOfRhJsaEQ?&wmode=opaque&enablejsapi=1&origin=https://www.wevolver.com" allowfullscreen="" class="fr-draggable" style="width: 766px; height: 436px;" frameborder="0" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-gtm-yt-inspected-7="true" id="439090068" title="LaserSnake2 - Laser cutting for nuclear decommissioning at Sellafield - a world first."></iframe>Researchers from Bristol University have just recently flown a drone over the Chernobyl Red Forest highlighting the site survey capabilities of drones applicable to all nuclear sites.<iframe src="https://www.youtube.com/embed/_Eto98XTm-4?&wmode=opaque&enablejsapi=1&origin=https://www.wevolver.com" allowfullscreen="" class="fr-draggable" style="width: 766px; height: 394px;" frameborder="0" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" data-gtm-yt-inspected-7="true" id="334628213" title="YouTube video player"></iframe>Hitachi-GE have also developed a &ldquo;shape-changing robot&rdquo; to characterise the internals of Fukushima. Designed to be passed through small gaps in a long cylindrical shape, it is then capable of morphing into a &ldquo;U&rdquo; shape for stability. Equipped with a radiation tolerant camera and dosimeter, multiple robots were deployed with valuable data returned.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNTU5NjY4MzQ5NTkyLVNoYXBlLWNoYW5naW5nIElSSUQtSGl0YWNoaSByb2JvdCAtIDQ1MC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib">However, one of them got stuck, which leads me to my next point.<h1>The problem with Robots</h1>I love robots, and I believe that robotic systems HAVE to and WILL have a huge part to play in harsh environments, but there are still things that have so far left deployment of robotic systems on the fringes of use. These include, but are not limited to:<ul><li>Robots are dumb: When compared to a human assessing a situation. The Hitachi shape-changing robot fell foul of a common problem with robotic systems, it got caught in a hole in the grating it was driving on it wasn&rsquo;t expecting and that could not be seen by the human operator with the robot not &ldquo;smart&rdquo; enough to avoid or raise a flag. Robots are only as smart as we make them!</li><li>Radiation effects: Robots readily survive longer than humans but there are still failures of the electronics in high dose areas.</li><li>Tether entanglement:&nbsp;Most robots (not including drones) are often required to be connected via tether. This is for safety, in-case the robot breaks, meaning it can be unceremoniously dragged out but causes issues with entanglement.</li><li>Robots require a skilled pilot: That skill-set is not common.</li><li>The industry isn&rsquo;t ready: When things have been done a certain way for a long time, it is difficult to change that. Not to mention all the legal licensing issues and who takes responsibility when something goes wrong?! Media storms surrounding the ethics of robots taking jobs and becoming our future overlords do not help (thanks a lot Terminator).</li></ul><h1>In Conclusion</h1>There is a great body of work being completed within industry and research institutions developing bespoke solutions for specific problems and there have been many successful deployments and also many unsuccessful deployments, which is all part of innovation! Not included above but deserve a mention with regards to innovation and deployments to Brokk and Seabotix robotic systems that are often used daily.To really get consistent robotic platform deployments in nuclear decommissioning, further innovation improving the capabilities of robotic platforms is required as well as upskilling of the workforce and events showcasing the technology to industry. Communication is key and the continued development of systems by all the engineers out there.<hr>This article is part of a series about the usage of robots in harsh environments, written by post-doctoral robotics researcher Matthew Nancekievill. Find the second article, on subsea environments,&nbsp;<a href="https://www.wevolver.com/article/robotics.for.harsh.environments.subsea" rel="noopener noreferrer" target="_blank">here.</a>

Decommissioning happens around us all the time, old buildings get torn down, coal power plants shutdown and vehicles get scrapped.

Robotics for Harsh Environments - Nuclear Decommissioning

Manufacturing

This is staging - but I edited this directly from the DB - woo wooPowered by <a href="https://www.froala.com/wysiwyg-editor?pb=1" title="Froala Editor">Froala Editor</a>

This is staging

Machines like the Stratasys Fortus 450mc can process high-temp 3D printer filament (credit: Stratasys)

High-temp 3D printer filaments are challenging to print, but they can be used to make vital end-use parts like automotive components.

High-Temp 3D Printer Filament: Material and Hardware Considerations

Investigating the basics of six-axis robots, how they are structured, the key components, advantages and applications in the industrial sector


What is a Six Axis Robot: Exploring the Versatile Powerhouse of Industrial Automation

Industrial process automation is changing manufacturing by using technology to reduce the need for human involvement. From robots assembling products to smart systems managing inventory, factories are being transformed. This article will explore the successful elements behind industrial automation.

Industrial Process Automation: The Future of Manufacturing

Delve into the basics of absolute encoders, its applications, advancements in technologies, calibration techniques, and the advantages over encoder types.


Absolute Encoder: Precision Positioning in the Digital Age

Cura tree supports were developed as an alternative to traditional linear supports, enabling geometries with overhangs and steep angles to be 3D printed while achieving greater printing efficiency in terms of print times, material usage, and post-processing. This innovative feature, integrated into the popular Cura slicing software, generates organic, tree-like structures that support certain elements of the 3D print throughout the printing process. In this article, we’ll be covering everything there is to know about Cura tree supports, including how they compare to normal supports, important tree support settings, pros and cons, and when tree supports are most beneficial.<h2 dir="ltr">Why do you need support structures?</h2>3D printing is unique among manufacturing processes for its ability to produce incredibly complex shapes. Some 3D printing processes, like Fused Deposition Modeling (FDM), however, need a bit of help sometimes to achieve these intricate geometries. Some support, if you will.&nbsp;3D printers struggle to print certain features, like overhangs and bridges, because the filament is not adequately reinforced and will succumb to gravity if it is printed in mid-air. That’s where support structures come in. Supports are automatically generated in slicer software programs such as Ultimaker Cura and enable 3D printers to produce parts with features like overhangs and bridges.&nbsp;Overhangs are shapes on a <a href="https://www.wevolver.com/article/how-to-make-a-3d-model-for-printing" target="_blank">3D model</a> that jut out at angles of over 45°. Bridges, for their part, are horizontal structures that typically connect two vertical structures. Supports are required to print both these elements so that the filament layers are supported as they are extruded.<h2 dir="ltr">Linear supports vs Tree supports</h2>There are two main types of support structure: linear supports—also known as normal supports—and tree supports. Linear supports are vertical structures that are printed straight up to support overhangs and bridges. This type of support structure reinforces the entire overhang area and typically consists of a solid shell and infill.[2]Tree supports, the subject of this article, are more organic in shape, appearing to grow like tree branches around the 3D model to support overhangs and bridges. One of the defining characteristics of tree supports is that they are printed wider at the base of the model and gradually taper off, providing adequate support while minimizing contact points with the 3D printed part. Tree supports are also hollow, consisting primarily of a shell, which is easy to remove post-printing.&nbsp;Recommended reading: <a href="https://www.wevolver.com/article/cura-support-settings-from-angles-to-z-distance" target="_blank" rel="noopener noreferrer">Cura Support Settings Explained</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjU0NTg0NDgzMzY4LXRyZWVfc3VwcG9ydC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" width="624" height="416" class="fr-fic fr-dii" alt="Ultimaker 3D printer while 3D model">Unlike linear supports, tree supports wrap around the 3D model, providing support directly where needed.<h2 dir="ltr" id="isPasted">How Cura Tree Supports Work</h2>In the FDM 3D printing process, a print head extrudes melted thermoplastic filament onto a build platform. As the material is deposited, it begins to solidify. This is repeated layer by layer until an object is built up. In general, supports are needed when the layers of the print do not have enough support from the layers underneath them.&nbsp;Cura tree supports differ from regular supports in that they can be printed at different angles, rather than straight up. This enables them to adapt to the printed model’s geometry easily. In other words, they are printed around the model. Cura tree supports ultimately provide direct reinforcement to overhangs using the tips of their branches. This unique approach not only provides adequate support, it also results in fewer contact points between the support structure and the printed model. In the end, this makes the tree supports easier to remove than more traditional linear supports. &nbsp;The algorithm that generates tree supports in Cura takes several factors into account when creating the support geometry. Specifically, it considers load distribution (branches are positioned to evenly distribute the weight of the supported structure), self-supporting angles (branches are generated at angles that allow them to be self-supporting), and minimal contact (the algorithm minimizes the contact points for optimal post-processing).In Cura slicer software, tree supports can be activated under “Support” settings. There are also several parameters related to tree supports that you can adjust. Below are some of the key Cura tree support settings you should know about[1]:<div dir="ltr" align="left"><table><tbody><tr><td>Support Placement</td><td>With this setting, makers can choose between two options: “touching build plate” and “everywhere”. Touching build plate will generate supports only using the build platform as a base. Everywhere, on the other hand, will generate supports from both the build plate and the 3D model, if needed.</td></tr><tr><td>Support overhang angle</td><td>Setting your support overhang angle will determine at what degree overhangs will require a support structure. All FDM 3D printers can print overhangs of up to 45° without supports, and many can handle angles of up to 50-55°.</td></tr><tr><td>Support branch angle</td><td>This setting is unique to tree supports. The support branch angle controls the maximum angle that tree supports will be printed at. A higher value for the support branch angle will result in more freedom for branches to be printed around the model (this means fewer contact points). That said, increasing the support branch angle too much can lead to less supportive branches. A lower support branch angle will result in more vertical branches that are more stable.</td></tr><tr><td>Support branch distance</td><td>This parameter determines how far the top of the support branches will be to the edge of the overhang. A lower value for branch distance will result in more contact points, which will provide greater reinforcement and increase the quality of the overhang. However, a smaller branch distance can also make the tree support branches harder to remove.</td></tr><tr><td>Support branch diameter</td><td>This setting controls the minimum width of the branch. In other words, how small the branch diameter will be at its thinnest point. A smaller branch diameter will reduce the amount of material usage, but a wider branch diameter will provide greater stability.</td></tr><tr><td>Collision resolution</td><td>This <a href="https://www.wevolver.com/article/best-ender-3-pro-cura-settings-temperature-speed-retraction-more" target="_blank">slicer setting</a> for tree supports ensures that the supports don’t intersect with the 3D model when they are generated. 0.2 mm is the default collision resolution setting in Cura. Increasing the value can lead to faster printing times, but lower quality tree supports.</td></tr></tbody></table></div><h2 dir="ltr">The Pros of Cura Tree Supports</h2>Cura tree supports have several benefits, which have made them increasingly popular amongst makers and professional 3D printing users. Let’s take a look at some of the main benefits tree supports offer.<h3 dir="ltr">Less material waste</h3>Open source Cura software developers first came up with tree supports as a way to reduce the amount of material waste generated by supports. They were successful in this effort: tree supports use significantly less material than standard supports because they are almost entirely hollow and because they taper in width. This helps to reduce material waste and material costs.&nbsp;<h3 dir="ltr">Faster printing time</h3>As an added bonus of using less material, tree supports are also faster to print than conventional support structures. Cura software will tell you how much material supports will use and how long a print will take, so you can directly compare standard and tree supports for a given print job. You can also compare the material usage in the same way.<h3 dir="ltr">Smoother surface finish</h3>Another reason to use tree supports is that they can improve the surface finish quality of 3D prints compared to traditional supports. This benefit is owed to the simple fact that tree supports are designed to minimize contact points with the 3D model. In some cases, the only touch points between the tree supports and the 3D printed object will be the tips of the branches that support the overhangs. Tree supports therefore require minimal post-processing and shouldn’t affect the quality of intricate or finely detailed 3D prints.<h3 dir="ltr">Easy support removal</h3>Easy support removal is another consequence of having minimal contact points between the tree supports and the 3D printed model. Normal supports can sometimes bond to the 3D printed model making removal challenging, even requiring tools like pliers or cutters to take them off. Tree supports on the other hand consist of a shell around the print with minimal contact points. In most cases, this means they can be peeled off the final print by hand without significant risk of damage.Recommended reading:<a href="https://www.wevolver.com/article/improving-your-3d-printing-success-rate-with-ultimaker-cura" target="_blank">&nbsp;Improving your 3D printing success rate with Ultimaker Cura</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjU0NTg0NDM0ODI5LXRyZWUtc3VwcG9ydC1leGFtcGxlLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib" alt="Cura 3D model with tree supports">Tree supports are generally easier to remove than linear supports because they have fewer contact points. Image Credits:&nbsp;<a href="https://support.ultimaker.com/hc/en-us/articles/360012612779-Support-settings" rel="noopener noreferrer" target="_blank">Ultimaker</a><h2 dir="ltr" id="isPasted">The Cons of Cura Tree Supports</h2>Now that we’ve seen the benefits of using tree supports, let’s take a look at the potential downsides.<h3 dir="ltr">Longer slicing times</h3>The main disadvantage of using tree supports is that the support structures require more processing power than traditional linear supports. Because tree supports have a more complex geometry than linear supports, they take longer to generate in slicing software. This can minimize the benefit of faster support printing times (though rarely negate it).<h3 dir="ltr">Less suitable for soluble PVA supports</h3>Due to their complexity in shape and geometry, tree supports can also present a challenge if you are using a <a href="https://www.wevolver.com/article/using-soluble-3d-printer-filament-to-build-support-structures" target="_blank">soluble support material such as PVA</a>. PVA is a harder material to print compared to PLA or ABS and some 3D printers can therefore struggle to achieve the finer shapes that characterize the tops of tree supports. Cura therefore recommends using its tree support function primarily for non-soluble support materials.<h3 dir="ltr">Cura tree support pros and cons summary:</h3><div dir="ltr" align="left"><table><tbody><tr><td>Cura Tree Support Pros</td><td>Cura Tree Support Cons</td></tr><tr><td>Less material waste</td><td>Longer slicing times</td></tr><tr><td>Faster printing times</td><td>Less suitable for soluble supports</td></tr><tr><td>Smoother surface finish</td><td> </td></tr><tr><td>Easier post-processing</td><td> </td></tr></tbody></table></div><h2 dir="ltr">When to use Cura Tree supports?</h2>While the disadvantages of Cura tree supports are minimal compared to the advantages, there is still a time and a place to use them. In some cases, standard 3D printing supports may be more beneficial. In others, tree supports are the clear way to go. There are three main scenarios where tree supports make the most sense.<h3 dir="ltr">If visual quality is a priority</h3>First, if you are printing an object where the visual quality is of the utmost importance, tree supports are highly beneficial. Because tree supports are designed to have fewer connection points to the 3D printed part, removal is easy and results in fewer marks or imperfections on the part’s surface.&nbsp;<h3 dir="ltr">If you want to reduce material waste</h3>Second, if you are trying to consume less filament, tree supports will generally use less material because they are hollow shells. If you need greater stability, you can also choose to print tree supports with a low infill density. Using less material for supports will help you minimize material waste and cut back on material costs in the long run.<h3 dir="ltr">If tight tolerances are needed</h3>Third, tree supports are highly beneficial if you are printing a component that requires tight tolerances. Because regular supports sometimes need to be cut off, makers need to sand down the support remnants from the part surface. Sanding and other post-processing steps can influence the part’s dimensional accuracy. Tree supports on the other hand require minimal post-processing (often no post-processing) and can be removed without affecting the part’s tolerances.&nbsp;Recommended reading:&nbsp;<a href="https://www.wevolver.com/article/how-to-remove-supports-from-3d-prints" target="_blank">How to Remove Supports from 3D Prints</a><h2 dir="ltr">Conclusion</h2>Whether you are a beginner or experienced maker, it is important to know what features are at your disposal when it comes to 3D printing. Still a relatively new option in Cura slicer, tree supports provide many advantages that makers may not yet be familiar with. With the knowledge in this article, however, you should be prepared to make the most out of automated tree supports and their print settings.As 3D printing continues to evolve, experimenting with tree supports in your next project can unlock new levels of creativity and efficiency. Whether you're working on intricate prototypes, custom parts, or artistic creations, incorporating tree supports can significantly enhance your 3D printing outcomes.<h2 dir="ltr">Frequently Asked Questions (FAQs)</h2>Q: Are Cura tree supports compatible with all 3D printers?&nbsp;A: Cura tree supports are compatible with most FDM (Fused Deposition Modeling) printers. However, it's always best to check your printer's specifications and ensure you're using the latest version of Cura for optimal compatibility.Q: Can tree supports be used with all types of filaments?&nbsp;A: Tree supports work well with most common filaments like PLA, ABS, and PETG. For less common 3D printing materials, it's recommended to test and adjust settings accordingly. Some flexible filaments may require special considerations and soluble filaments like PVA are generally not recommended for use with tree supports.Q: How do I optimize tree support settings for very small, detailed prints?&nbsp;A: For small, detailed prints, consider reducing the branch diameter and increasing the branch density. Adjust the "Support Roof" settings to ensure proper support for fine details. Experiment with different overhang angles to find the optimal balance between support and print quality.Q: Are tree supports suitable for large-scale prints?&nbsp;A: Yes, tree supports are excellent for large-scale prints. They can significantly reduce material usage and print time compared to traditional supports. For very large prints, consider increasing the branch diameter and adjusting the branch angle for added stability.Q: How do tree supports compare to traditional supports in terms of print time?&nbsp;A: In most cases, tree supports reduce print time compared to traditional supports. The exact time savings depend on the model's complexity. However, the slicer generating time for tree supports is slower than for linear supports.Q: Are there any specific model orientations that work best with tree supports?&nbsp;A: While tree supports are versatile, orienting your model to minimize overhangs can optimize their effectiveness. For mechanical parts, consider orientations that align the broadest flat surfaces with the build plate.<h2 dir="ltr">References</h2>[1] Tree supports: What are they and how do they work? [Internet]. Ultimaker, 2024. Available from:&nbsp;<a href="https://ultimaker.com/learn/tree-supports-what-are-they-and-how-do-they-work/" target="_blank">https://ultimaker.com/learn/tree-supports-what-are-they-and-how-do-they-work/</a>&nbsp;[2] UltiMaker Cura - Support settings [Internet]. Ultimaker, March 3, 2024. Available from:&nbsp;<a href="https://support.ultimaker.com/s/article/1667417606331" target="_blank">https://support.ultimaker.com/s/article/1667417606331</a>&nbsp;

Cura tree supports are a relatively new feature that offers several benefits, like less material consumption and easier support removal