Laser-Folded Actuators With Freely Moving Released Parts

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Solution Overview

Problem

Current self-folding techniques cannot create suspended, freely moving parts without additional handling, and there is a lack of methods for using laser ablation propulsion in remotely self-folded manufacturing processes to position and propel released components.

Innovation Solution

A method and apparatus using a laser to form and release a three-dimensional actuator from sheet stock, employing laser cutting and folding to create complex multi-component parts, and utilizing laser ablation propulsion to move the released components, allowing remote folding and assembly of complex parts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If self-folding techniques are used to create complex 3D structures from 2D sheet stock, then manufacturing complexity is reduced and fabrication cost decreases, but the ability to create suspended, freely moving parts is lost

Engineering Contradiction:

Improvefabrication costVSAvoidability to create freely moving parts

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The structure is divided into multiple separable components that are initially connected by sacrificial material. The laser selectively removes this sacrificial material to release individual movable parts from the base structure, enabling independent motion while maintaining the benefit of integrated fabrication.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Sacrificial material is strategically placed between components that need to move relative to each other. The laser selectively removes (extracts) this sacrificial material to create gaps and release movable parts, transforming the rigid self-folded structure into one with controlled freedom of motion.

Inventive Principle:

Principle #2Taking out (Extraction)

2Manufacturing precision

If traditional laser cutting is used to create parts, then manufacturing precision is achieved, but additional handling and assembly steps are required

Engineering Contradiction:

Improvelaser cutting precisionVSAvoidhandling requirements

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

Multiple functions are combined into a single laser operation: the laser performs cutting, folding, and release of components simultaneously. The sacrificial material removal integrates the separation function with the fabrication process, eliminating the need for separate handling and assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The structure is designed to self-assemble and self-release through the laser process. The sacrificial material acts as a built-in release mechanism that requires no external intervention—simply removing the sacrificial material causes the structure to automatically configure itself with movable parts in their correct positions.

Inventive Principle:

Principle #25Self-service

3Extent of automation

If laser ablation propulsion is applied to move released components, then manual handling is eliminated and automation increases, but energy consumption increases

Engineering Contradiction:

Improveremote positioning capabilityVSAvoidlaser energy consumption

Core Design Contradiction:

Extent of automationVSUse of energy by moving object

Solution Approach 1:

The mechanical handling system (robotic arms, grippers, conveyors) is replaced with a field-based laser ablation propulsion system. The laser creates localized thrust by ablating material at the component surface, propelling parts to their destinations without mechanical contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The laser parameters (power, pulse duration, scanning speed) are dynamically adjusted to optimize propulsion efficiency. By controlling the ablation rate and thrust generation, the system achieves effective component positioning while managing energy consumption through parameter optimization.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables the creation of self-folded, freely moving parts and the remote positioning of released components, enhancing the capability to assemble complex multi-component systems and reducing the need for manual handling, with potential applications in manufacturing and 4D printing.

Implementation Method 1

utilizing laser ablation propulsion to move the released components

Methodology Applied

Scientific EffectLaser ablation propulsion: Laser Ablation

Implementation Method 2

use of a Laser for Release and Propulsion in a Self-Folding Manufacturing Process

Methodology Applied

Scientific EffectAblation: Ablation

Implementation Method 3

where plastic strains are generated to fold a part using controlled heating by the laser

Methodology Applied

Scientific EffectTemperature gradient mechanism: Temperature Gradient

Implementation Method 4

with TGM and BM referring to temperature gradient and buckling mechanisms used for up and down folds

Methodology Applied

Scientific EffectBuckling:

Data Source

PatentUS12011782B2Method and apparatus for performing contactless laser fabrication and propulsion of freely moving structures

Publication Date: 2024.06.18 UNITED STATES OF AMERICA THE AS REPRESENTED BY THE SEC OF THE ARMY

AI summary

A method and apparatus for using a laser to form and release an element of an actuator. The method comprising forming an actuator from sheet stock using a laser, where the actuator is three dimensional; releasing an element of the actuator from the sheet stock using the laser; and moving the released part relative to the sheet stock using laser ablation propulsion.