VTechWorks Repository :: Browsing by Author "Zheng, Xiaoyu"

Browsing by Author "Zheng, Xiaoyu"

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3D Coiling at the Protrusion Tip: New Perspectives on How Cancer Cells Sense Their Fibrous Surroundings
Mukherjee, Apratim (Virginia Tech, 2021-05-24)
Cancer metastasis, the spread of cancer from the primary site to distant regions in the body, is the major cause of cancer mortality, accounting for almost 90% of cancer related deaths. During metastasis, cancer cells from the primary tumor initially probe the surrounding fibrous tumor microenvironment (TME) prior to detaching and subsequently migrating towards the blood vessels for further dissemination. It has widely been acknowledged that the biophysical cues provided by the fibrous TME greatly facilitate the metastatic cascade. Consequently, there has been a tremendous wealth of work devoted towards elucidating different modes of cancer cell migration. However, our knowledge of how cancer cells at the primary tumor site initially sense their fibrous surroundings prior to making the decision to detach and migrate remains in infancy. In part, this is due to the lack of a fibrous in vitro platform that allows for precise, repeatable manipulation of fiber characteristics. In this study, we use the non-electrospinning, Spinneret based Tunable Engineered Parameters (STEP) technique to manufacture suspended nanofiber networks with exquisite control on fiber dimensions and network architecture and use these networks to investigate how single cancer cells biophysically sense fibers mimicking in vivo dimensions. Using high spatiotemporal resolution imaging (63x magnification/1-second imaging interval), we report for the first time, that cancer cells sense individual fibers by coiling (i.e. wrapping around the fiber axis) at the tip of a cell protrusion. We find that coiling dynamics are mediated by both the fiber curvature and the metastatic capacity of the cancer cells with less aggressive cancer cells showing diminished coiling. Based on these results, we explore the possibility of using coiling in conjunction with other key biophysical metrics such as cell migration dynamics and forces exerted in the development of a genetic marker independent, biophysical predictive tool for disease progression. Finally, we identify the membrane curvature sensing Insulin Receptor tyrosine kinase Substrate protein of 53 kDa (IRSp53) as a key regulator of protrusive activity with IRSp53 knockout (KO) cells exhibiting significantly slower protrusion dynamics and diminished coil width compared to their wild-type (WT) counterparts. We demonstrate that the hindered protrusive activity ultimately translates to impaired contractility, alteration in the nucleus shape and slower migration dynamics, thus highlighting the unique role of IRSp53 as a signal transducer – linking the protrusive activity at the cell membrane to changes in cytoskeletal contractility. Overall, these findings offer novel perspectives to our understanding of how cancer cells biophysically sense their fibrous surroundings. The results from this study could ultimately pave the way for elucidating the precise fiber configurations that either facilitate or hinder cancer cell invasion, allowing for the development of new therapeutics in the long term that could inhibit the metastatic cascade at a relatively nascent stage and yield a more promising prognosis in the perennial fight against cancer.
Adaptive optical beam steering and tuning system based on electrowetting driven fluidic rotor
Cheng, Weifeng; Liu, Jiansheng; Zheng, Zheng; He, Xukun; Zheng, Bowen; Zhang, Hualiang; Cui, Huachen; Zheng, Xiaoyu; Zheng, Tao; Gnade, Bruce E.; Cheng, Jiangtao (2020-01-27)
Reconfigurable beam steering components are indispensable to support optical and photonic network systems operating with high adaptability and with various functions. Currently, almost all such components are made of solid parts whose structures are rigid, and hence their functions are difficult to be reconfigured. Also, optical concentration beam steering is still a very challenging problem compared to radio frequency/microwave steering. Here we show a watermill-like beam steering system that can adaptively guide concentrating optical beam to targeted receivers. The system comprises a liquid droplet actuation mechanism based on electrowetting-on-dielectric, a superlattice-structured rotation hub, and an enhanced optical reflecting membrane. The specular reflector can be adaptively tuned within the lateral orientation of 360 degrees, and the steering speed can reach similar to 353.5 degrees s(-1). This work demonstrates the feasibility of driving a macro-size solid structure with liquid microdroplets, opening a new avenue for developing reconfigurable components such as optical switches in next-generation sensor networks.
Additive manufacturing of complex micro-architected graphene aerogels
Hensleigh, Ryan M.; Cui, Huachen; Oakdale, James S.; Ye, Jianchao C.; Campbell, Patrick G.; Duoss, Eric B.; Spadaccini, Christopher M.; Zheng, Xiaoyu; Worsley, Marcus A. (Royal Society of Chemistry, 2018-08-13)
3D graphene foams exhibit immense degradation of mechanical properties. Micro-architecture can alleviate this problem, but no current technique meets the manufacturing requirements. Herein we developed a light-based 3D printing process to create hierarchical graphene structures with arbitrary complexity and order-of-magnitude finer features, showing enhanced mechanical properties at decreasing density.
Additive Manufacturing of Copper via Binder Jetting of Copper Nanoparticle Inks
Bai, Yun (Virginia Tech, 2018-06-01)
This work created a manufacturing process and material system based on binder jetting Additive Manufacturing to process pure copper. In order to reduce the sintered part porosity and shape distortion during sintering, the powder bed voids were filled with smaller particles to improve the powder packing density. Through the investigation of a bimodal particle size powder bed and nanoparticle binders, this work aims to develop an understanding of (i) the relationship between printed part properties and powder bed particle size distribution, and (ii) the binder-powder interaction and printed primitive formation in binder jetting of metals. Bimodal powder mixtures created by mixing a coarse powder with a finer powder were investigated. Compared to the parts printed with the monosized fine powder constituent, the use of a bimodal powder mixture improved the powder flowability and packing density, and therefore increased the green part density (8.2%), reduced the sintering shrinkage (6.4%), and increased the sintered density (4.0%). The deposition of nanoparticles to the powder bed voids was achieved by three different metal binders: (i) a nanoparticles suspension in an existing organic binder, (ii) an inorganic nanosuspension, and (iii) a Metal-Organic-Decomposition ink. The use of nanoparticle binders improved the green part density and reduced the sintering shrinkage, which has led to an improved sintered density when high binder saturation ratios were used. A new binding mechanism based on sintering the jetted metal nanoparticles was demonstrated to be capable of (i) providing a permanent bonding for powders to improve the printed part structural integrity, and (ii) eliminating the need for organic adhesives to improve the printed part purity. Finally, the binder-powder interaction was studied by an experimental approach based on sessile drop goniometry on a powder bed. The dynamic contact angle of binder wetting capillary pores was calculated based on the binder penetration time, and used to describe the powder permeability and understand the binder penetration depth. This gained understanding was then used to study how the nanoparticle solid loading in a binder affect the binder-powder interactions and the printed primitive size, which provided an understanding for determining material compatibility and printing parameters in binder jetting.
Context-Aware Resource Management and Performance Analysis of Millimeter Wave and Sub-6 GHz Wireless Networks
Semiari, Omid (Virginia Tech, 2017-08-28)
Emerging wireless networks are foreseen as an integration of heterogeneous spectrum bands, wireless access technologies, and backhaul solutions, as well as a large-scale interconnection of devices, people, and vehicles. Such a heterogeneity will range from the proliferation of multi-tasking user devices with different capabilities such as smartphones and tablets to the deployment of multi-mode access points that can operate over heterogeneous frequency bands spanning both sub-6 GHz microwave and high-frequency millimeter wave (mmW) frequencies bands. This heterogeneous ecosystem will yield new challenges and opportunities for wireless resource management. On the one hand, resource management can exploit user and network-specific context information, such as application type, social metrics, or operator pricing, to develop application-driven, context-aware networks. Similarly, multiple frequency bands can be leveraged to meet the stringent and heterogeneous quality-of-service (QoS) requirements of the new wireless services such as video streaming and interactive gaming. On the other hand, resource management in such heterogeneous, multi-band, and large-scale wireless systems requires distributed frameworks that can effectively utilize all available resources while operating with manageable overhead. The key goal of this dissertation is therefore to develop novel, self-organizing, and low-complexity resource management protocols -- using techniques from matching theory, optimization, and machine learning -- to address critical resource allocation problems for emerging heterogeneous wireless systems while explicitly modeling and factoring diverse network context information. Towards achieving this goal, this dissertation makes a number of key contributions. First, a novel context-aware scheduling framework is developed for enabling dual-mode base stations to efficiently and jointly utilize mmW and microwave frequency resources while maximizing the number of user applications whose stringent delay requirements are satisfied. The results show that the proposed approach will be able to significantly improve the QoS per application and decrease the outage probability. Second, novel solutions are proposed to address both network formation and resource allocation problems in multi-hop wireless backhaul networks that operate at mmW frequencies. The proposed framework motivates collaboration among multiple network operators by resource sharing to reduce the cost of backhauling, while jointly accounting for both wireless channel characteristics and economic factors. Third, a novel framework is proposed to exploit high-capacity mmW communications and device-level caching to minimize handover failures as well as energy consumption by inter-frequency measurements, and to provide seamless mobility in dense heterogeneous mmW-microwave small cell networks (SCNs). Fourth, a new cell association algorithm is proposed, based on matching theory with minimum quota constraints, to optimize load balancing in integrated mmW-microwave networks. Fifth, a novel medium access control (MAC) protocol is proposed to dynamically manage the wireless local area network (WLAN) traffic jointly over the unlicensed 60 GHz mmW and sub-6 GHz bands to maximize the saturation throughput and minimize the delay experienced by users. Finally, a novel resource management approach is proposed to optimize device-to-device (D2D) communications and improve traffic offload in heterogeneous wireless SCNs by leveraging social context information that is dynamically learned by the network. In a nutshell, by providing novel, context-aware, and self-organizing frameworks, this dissertation addresses fundamentally challenging resource management problems that mainly stem from large scale, stringent service requirements, and heterogeneity of next-generation wireless networks.
Cyber-Physical Security for Additive Manufacturing Systems
Sturm, Logan Daniel (Virginia Tech, 2020-12-16)
Additive manufacturing (AM) is a growing section of the advanced manufacturing field and is being used to fabricate an increasing number of critical components, from aerospace components to medical implants. At the same time, cyber-physical attacks targeting manufacturing systems have continued to rise. For this reason, there is a need to research new techniques and methods to ensure the integrity of parts fabricated on AM systems. This work seeks to address this need by first performing a detailed analysis of vulnerabilities in the AM process chain and how these attack vectors could be used to execute malicious part sabotage attacks. This work demonstrated the ability of an internal void attack on the .STL file to reduce the yield load of a tensile specimen by 14% while escaping detection by operators. To mitigate these vulnerabilities, a new impedance-based approach for in situ monitoring of AM systems was created. Two techniques for implementing this approach were investigated, direct embedding of sensors in AM parts, and the use of an instrumented fixture as a build plate. The ability to detect changes in material as small as 1.38% of the printed volume (53.8 mm3) on a material jetting system was demonstrated. For metal laser powder bed fusion systems, a new method was created for representing side-channel meltpool emissions. This method reduces the quantity of data while remaining sensitive enough to detect changes to the toolpath and process parameters caused by malicious attacks. To enable the SCMS to validate part quality during fabrication required a way to receive baseline part quality information across an air-gap. To accomplish this a new process noise tolerant method of cyber-physical hashing for continuous data sets was presented. This method was coupled with new techniques for the storage, transmission, and reconstructing of the baseline quality data was implemented using stacks of "ghost" QR codes stored in the toolpath to transmit information through the laser position. A technique for storing and transmitting quality information in the toolpath files of parts using acoustic emissions was investigated. The ATTACH (additive toolpath transmission of acoustic cyber-physical hash) method used speed modulation of infill roads in a material extrusion system to generate acoustic tones containing quality information about the part. These modulations were able to be inserted without affecting the build time or requiring additional material and did not affect the quality of the part that contained them. Finally, a framework for the design and implementation of a SCMS for protecting AM systems against malicious cyber-physical part sabotage attacks was created. The IDEAS (Identify, Define, Establish, Aggregate, Secure) framework provides a detailed reference for engineers to use to secure AM systems by leveraging the previous work in vulnerability assessment, creation of new side-channel monitoring techniques, concisely representing quality data, and securely transmitting information to air-gapped systems through physical emissions.
Design and Additive Manufacturing of Carbon-Fiber Reinforced Polymer Microlattice with High Stiffness and High Damping
Kadam, Ruthvik Dinesh (Virginia Tech, 2019-10-17)
Carbon fiber reinforced polymer (CFRP) composites are known for their high stiffness-to-weight and high strength-to-weight ratios and hence are of great interest in several engineering fields such as aerospace, automotive and defense. However, despite their light weight, high stiffness and high strength, their application in these fields is limited due to their poor energy dissipation and vibration damping capabilities. This thesis presents a two-phase microlattice design to overcome this problem. To realize this design, a novel tape casting integrated multi-material stereolithography system is developed and mechanical properties of samples fabricated using this system are evaluated. The design incorporating a stiff phase (CFRP) and a high loss phase, exhibiting high stiffness as well as high damping, is studied via analytical and experimental approaches. To investigate its damping performance, mechanical properties at small-strain and large-strain regimes are measured through dynamic material analysis (DMA) and quasi-static cyclic compression tests respectively. It is seen that both intrinsic (small-strain) and structural (large-strain) damping in terms of a figure of merit (FOM), E1/3tanδ/ρ, can be enhanced by a small addition of a high loss phase in Reuss configuration. Moreover, it is seen that structural damping is improved at low relative densities due to the presence of elastic buckling during deformation. For design usefulness, tunability maps, displaying FOM in terms of design parameters, are developed by curve fitting of experimental measurements. The microlattice design is also evaluated quantitatively by comparing it with existing families of materials in a stiffness-loss map, which shows that the design is as stiff as commercial CFRP composites and as dissipative as elastomers.
Design and Manufacturing of Hierarchical Multi-Functional Materials Via High Resolution additive Manufacturing
Karch, Matthias Ottmar (Virginia Tech, 2017-09-28)
This master's thesis deals with the challenges of undesirable thermal expansion in lightweight materials. Thermal expansion of parts or components can lead to malfunction or breakdowns of complete systems in demanding environment where a large temperature gradient often exists. This work investigates a class of lightweight materials of which the thermal expansion coefficient can be controlled. Moreover, an additive manufacturing approach to produce these thermal management materials with high fidelity and reliability are critical to reach this goal. To achieve these two major research objectives analytic predictions, simulations, and measurement of thermal expansion coefficient with respect to temperature changes are conducted. Design and optimization of a high precision multi-material manufacturing apparatus has been conducted, leading to significant increase in production quality including reliability, efficiency, and costs.
Design, Analysis and Fabrication of Complex Structures using Voxel-based modeling for Additive Manufacturing
Tedia, Saish (Virginia Tech, 2017-11-20)
A key advantage of Additive Manufacturing (AM) is the opportunity to design and fabricate complex structures that cannot be made via traditional means. However, this potential is significantly constrained by the use of a facet-based geometry representation (e.g., the STL and the AMF file formats); which do not contain any volumetric information and often, designing/slicing/printing complex geometries exceeds the computational power available to the designer and the AM system itself. To enable efficient design and fabrication of complex/multi-material complex structures, several algorithms are presented that represent and process solid models as a set of voxels (three-dimensional pixels). Through this, one is able to efficiently realize parts featuring complex geometries and functionally graded materials. This thesis specifically aims to explore applications in three distinct fields namely, (i) Design for AM, (ii) Design for Manufacturing (DFM) education, and (iii) Reverse engineering from imaging data wherein voxel-based representations have proven to be superior to the traditional AM digital workflow. The advantages demonstrated in this study cannot be easily achieved using traditional AM workflows, and hence this work emphasizes the need for development of new voxel based frameworks and systems to fully utilize the capabilities of AM.
Design, Analysis, and Application of Architected Ferroelectric Lattice Materials
Wei, Amanda Xin (Virginia Tech, 2019-06-21)
Ferroelectric materials have been an area of keen interest for researchers due to their useful electro-mechanical coupling properties for a range of modern applications, such as sensing, precision actuation, or energy harvesting. The distribution of the piezoelectric coefficients, which corresponds to the piezoelectric properties, in traditional crystalline ferroelectric materials are determined by their inherent crystalline structure. This restriction limits the tunability of their piezoelectric properties. In the present work, ferroelectric lattice materials capable of a wide range of rationally designed piezoelectric coefficients are achieved through lattice micro-architecture design. The piezoelectric coefficients of several lattice designs are analyzed and predicted using an analytical volume-averaging approach. Finite element models were used to verify the analytical predictions and strong agreement between the two sets of results were found. Select lattice designs were additively manufactured using projection microstereolithography from a PZT-polymer composite and their piezoelectric coefficients experimentally verified and also found to be in agreement with the analytical and numerical predictions. The results show that the use of lattice micro-architecture successfully decouples the dependency of the piezoelectric properties on the material's crystalline structure, giving the user a means to tune the piezoelectric properties of the lattice materials. Real-world application of a ferroelectric lattice structure is demonstrated through application as a multi-directional stress sensor.
Designing Scaffolds for Directed Cell Response in Tissue Engineering Scaffolds Fabricated by Vat Photopolymerization
Chartrain, Nicholas (Virginia Tech, 2019-12-04)
Vat photopolymerization (VP) is an additive manufacturing (AM) technology that permits the fabrication of parts with complex geometries and feature sizes as small as a few microns. These attributes make VP an attractive option for the fabrication of scaffolds for tissue engineering. However, there are few printable materials with low cytotoxicity that encourage cellular adhesion. In addition, these resins are not readily available and must be synthesized. A novel resin based on 2-acrylamido-2-methyl-1-propanesulfonic acid (NaAMPS) and poly(ethylene glycol) diacrylate (PEGDA) was formulated and printed using VP. The mechanical properties, water content, and high fidelity of the scaffold indicated promise for use in tissue engineering applications. Murine fibroblasts were observed to successfully adhere and proliferate on the scaffolds. The growth, migration, and differentiation of a cell is known to dependent heavily on its microenvironment. In engineered constructs, much of this microenvironment is provided by the tissue scaffold. The physical environment results from the scaffold's geometrical features, including pore shape and size, porosity, and overall dimensions. Each of these parameters are known to affect cell viability and proliferation, but due to the difficulty of isolating each parameter when using scaffold fabrication techniques such as porogen leaching and gas foaming, conflicting results have been reported. Scaffolds with pore sizes ranging from 200 to 600 μm were fabricated and seeded with murine fibroblasts. Other geometric parameters (e.g., pore shape) remained consistent between scaffold designs. Inhomogeneous cell distributions and fewer total cells were observed in scaffolds with smaller pore sizes (200-400 μm). Scaffolds with larger pores had higher cell densities that were homogeneously distributed. These data suggest that tissue scaffolds intended to promote fibroblast proliferation should be designed to have pore at least 500 μm in diameter. Techniques developed for selective placement of dissimilar materials within a single VP scaffold enabled spatial control over cellular adhesion and proliferation. The multi-material scaffolds were fabricated using an unmodified and commercially available VP system. The material preferences of murine fibroblasts which resulted in their inhomogeneous distribution within multi-material scaffolds were confirmed with multiple resins and geometries. These results suggest that multi-material tissue scaffolds fabricated with VP could enable multiscale organization of cells and material into engineered constructs that would mimic the function of native tissue.
Development of High-Performance Optofluidic Sensors on Micro/Nanostructured Surfaces
Cheng, Weifeng (Virginia Tech, 2020-01-22)
Optofluidic sensing utilizes the advantages of both microfluidic and optical science to achieve tunable and reconfigurable high-performance sensing purpose, which has established itself as a new and dynamic research field for exciting developments at the interface of photonics, microfluidics, and the life sciences. With the trend of developing miniaturized electronic devices and integrating multi-functional units on lab-on-a-chip instruments, more and more desires request for novel and powerful approaches to integrating optical elements and fluids on the same chip-scale system in recent years. By taking advantage of the electrowetting phenomenon, the wettability of liquid droplet on micro/nano-structured surfaces and the Leidenfrost effect, this doctoral research focuses on developing high-performance optofluidic sensing systems, including optical beam adaptive steering, whispering gallery mode (WGM) optical sensing, and surface-enhanced Raman spectroscopy (SERS) sensing. A watermill-like beam steering system is developed that can adaptively guide concentrating optical beam to targeted receivers. The system comprises a liquid droplet actuation mechanism based on electrowetting-on-dielectric, a superlattice-structured rotation hub, and an enhanced optical reflecting membrane. The specular reflector can be adaptively tuned within the lateral orientation of 360°, and the steering speed can reach ~353.5°/s. This work demonstrates the feasibility of driving a macro-size solid structure with liquid microdroplets, opening a new avenue for developing reconfigurable components such as optical switches in next-generation sensor network. Furthermore, the WGM sensing system is demonstrated to be stimulated along the meridian plane of a liquid microdroplet, instead of equatorial plane, resting on a properly designed nanostructured chip surface. The unavoidable deformation along the meridian rim of the sessile microdroplet can be controlled and regulated by tailoring the nanopillar structures and their associated hydrophobicity. The nanostructured superhydrophobic chip surface and its impact on the microdroplet morphology are modeled by Surface Evolver (SE), which is subsequently validated by the Cassie-Wenzel theory of wetting. The influence of the microdroplet morphology on the optical characteristics of WGMs is further numerically studied using the Finite-Difference Time-Domain method (FDTD) and it is found that meridian WGMs with intrinsic quality factor Q exceeding 104 can exist. Importantly, such meridian WGMs can be efficiently excited by a waveguiding structure embedded in the planar chip, which could significantly reduce the overall system complexity by eliminating conventional mechanical coupling parts. Our simulation results also demonstrate that this optofluidic resonator can achieve a sensitivity as high as 530 nm/RIU. This on-chip coupling scheme could pave the way for developing lab-on-a-chip resonators for high-resolution sensing of trace analytes in various applications ranging from chemical detections, biological reaction processes to environmental protection. Lastly, this research reports a new type of high-performance SERS substrate with nanolaminated plasmonic nanostructures patterned on a hierarchical micro/nanostructured surface, which demonstrates SERS enhancement factor as high as 1.8 x 107. Different from the current SERS substrates which heavily relies on durability-poor surface structure modifications and various chemical coatings on the platform surfaces which can deteriorate the SERS enhancement factor (EF) as the coating materials may block hot spots, the Leidenfrost effect-inspired evaporation approach is proposed to minimize the analyte deposition area and maximize the analyte concentration on the SERS sensing substrate. By intentionally regulating the temperature of the SERS substrate during evaporation process, the Rhodamine 6G (R6G) molecules inside a droplet with an initial concentration of 10-9 M is deposited within an area of 450 μm2, and can be successfully detected with a practical detection time of 0.1 s and a low excitation power of 1.3 mW.
Fog Harvesting: Inspired by Spider Silk
Cen, Yijia (Virginia Tech, 2020-01-29)
The water crisis has been an increasing challenge in some places in the world. One proposed solution that has drawn lots of attention is fog harvesting. A commonly used fog collector is a vertical mesh, usually made of poly materials. Small water droplets can easily get pinned and quick evaporation is the major common challenge for vertical meshes. Coating the fog mesh with superhydrophobic chemicals is one of the solutions. However, superhydrophobicity is not durable and it may contaminate the collected water. In addition, it requires a high professional maintenance and laboratory operation standard. As a result, it is impractical to set such fog collectors in regions and countries with water crisis. Low cost, harmless, easily fabricated, higher coalesce rate and low maintenance are the five pillars for this research. This thesis topic is inspired by spider silk's ability to direct water droplets to certain locations to further enhance water collecting rate. This directional droplet movement is caused by spindle-knot and joint structure on the biomimetic silk. The spindle-knot is randomly porous, and the joint is stretched porous. In addition, the spindle-knot has a tilted angle β above the joint region. Due to these unique structures, there are three droplet movement controlling forces – surface tension force, hysteresis force, and Laplace pressure force. This thesis presents detailed equation derivations for each driving force in the introduction section. Spindle-knot is the pivot point to direct water, forming the spindle-knot structure is another focus of this thesis. Fluid coating and dip-coating with dimethylformamide (DMF), a solvent with a low evaporation rate, is the highly used methods to form the spindle-knot structures due to its simple setup and low cost. However, DMF is an extremely hazardous organic compound, and it requires high laboratory operation standards. In the second section of this thesis, DMF has been replaced with water/ethanol and photocurable materials to construct the spindle-knots. Furthermore, Additive manufacturing (3D printing method) was adopted to synthesize bionic spider web with spindle-knot structures.
An improved effective method for generating 3D printable models from medical imaging
Rathod, Gaurav Dilip (Virginia Tech, 2017-11-16)
Medical practitioners rely heavily on visualization of medical imaging to get a better understanding of the patient's anatomy. Most cancer treatment and surgery today are performed using medical imaging. Medical imaging is therefore of great importance to the medical industry. Medical imaging continues to depend heavily on a series of 2D scans, resulting in a series of 2D photographs being displayed using light boxes and/or computer monitors. Today, these 2D images are increasingly combined into 3D solid models using software. These 3D models can be used for improved visualization and understanding of the problem at hand, including fabricating physical 3D models using additive manufacturing technologies. Generating precise 3D solid models automatically from 2D scans is non-trivial. Geometric and/or topologic errors are common, and often costly manual editing is required to produce 3D solid models that sufficiently reflect the actual underlying human geometry. These errors arise from the ambiguity of converting from 2D data to 3D data, and also from inherent limitations of the .STL fileformat used in additive manufacturing. This thesis proposes a new, robust method for automatically generating 3D models from 2D scanned data (e.g., computed tomography (CT) or magnetic resonance imaging (MRI)), where the resulting 3D solid models are specifically generated for use with additive manufacturing. This new method does not rely on complicated procedures such as contour evolution and geometric spline generation, but uses volume reconstruction instead. The advantage of this approach is that the original scan data values are kept intact longer, so that the resulting surface is more accurate. This new method is demonstrated using medical CT data of the human nasal airway system, resulting in physical 3D models fabricated via additive manufacturing.
Improving the Strength of Binder Jetted Pharmaceutical Tablets Through Tailored Polymeric Binders and Powders
Ma, Da (Virginia Tech, 2020-11-25)
Additive Manufacturing (AM) provides a unique opportunity for fabrication of personalized medicine, where each oral dosage could be tailored to satisfy specific needs of each individual patient. Binder jetting, an easily scalable AM technique that is capable of processing the powdered raw material used by tablet manufacturers, is an attractive means for producing individualized pharmaceutical tablets. However, due to the low density of the printed specimens and incompatible binder-powder combination, tablets fabricated by this AM technology suffer from poor strength. The research is introducing an additional composition in the binder jetting powder bed (e.g., powdered sugar) could significantly enhance the compressive strength of the as-fabricated tablets, as compared with those tablets fabricated without the additional powder binding agent. However, no previous research demonstrated comprehensive approaches to enhance the poor performance of the 3D printed tablets. Therefore, the goal of this work is to identify processing techniques for improving the strength of binder jetted tablets, including the use of (i) novel jettable polymeric binders (e.g., 4-arm star polyvinylpyrrolidone (PVP), DI water, and different i) weight percentage of sorbitol binder) and (ii) introducing an additional powder binding agent into the powder bed (e.g.., different wt% of powdered sugar).
Investigating the Process-Structure-Property Relationships in Vat Photopolymerization to Enable Fabrication of Performance Polymers
Meenakshisundaram, Viswanath (Virginia Tech, 2021-01-07)
Vat photopolymerization's (VP) use in large-scale industrial manufacturing is limited due to poor scalability, and limited catalogue of engineering polymers. The challenges in scalability stem from an inherent process paradox: the feature resolution, part size, and manufacturing throughput cannot be maximized simultaneously in standard VP platforms. In addition, VP's inability to process viscous and high-molecular weight engineering polymers limits the VP materials catalogue. To address these limitations, the research presented in this work was conducted in two stages: (1) Development and modeling of new VP platforms to address the scalability and viscosity challenges, and (2) Investigating the influence of using the new processes on the cured polymer network structure and mechanical properties. First, a scanning mask projection vat photopolymerization (S-MPVP) system was developed to address the scalability limitations in VP systems. The process paradox was resolved by scanning the mask projection device across the resin surface while simultaneously projecting the layer as a movie. Using actual projected pixel irradiance distribution, a process model was developed to capture the interaction between projected pixels and the resin, and predict the resulting cure profile with an error of 2.9%. The S-MPVP model was then extended for processing heterogeneous UV scattering resins (i.e. UV curable polymer colloids). Using computer vision, the scattering of incident UV radiation on the resin surface was successfully captured and used to predict scattering-compensated printing parameters (bitmap pattern, exposure time , scanning speed). The developed reverse-curing model was used to successfully fabricate complex features using photocurable SBR latex with XY errors < 1.3%. To address the low manufacturing throughput of VP systems, a recoat-less, volumetric curing VP system that fabricates parts by continuously irradiating the resin surface with a movie composed of different gray-scaled bitmap images ( Free-surface movie mask projection (FreeMMaP)) was developed. The effect of cumulative exposure on the cure profile (X,Y,Z dimensions) was investigated and used to develop an iterative gray-scaling algorithm that generated a combination of gray-scaled bitmap images and exposure times that result in accurate volumetric curing (errors in XY plane and Z axis < 5% and 3% respectively). Results of this work demonstrate that the elimination of the recoating process increased manufacturing speed by 8.05 times and enabled high-resolution fabrication with highly viscous resins or soft gels. Then, highly viscous resins were made processible in VP systems by using elevated processing temperatures to lower resin viscosity. New characterization techniques were developed to determine the threshold printing temperature and time that prevented the onset of thermally-induced polymerization. The effect of printing temperature on curing, cured polymer structure, cured polymer mechanical properties, and printable aspect ratio was also investigated using diacrylate and dimethacrylate resins. Results of this investigation revealed increasing printing temperature resulted in improvements in crosslink density, tensile strength, and printability. However, presence of hydroxl groups on the resin backbone caused deterioration of crosslink density, mechanical properties, and curing properties at elevated printing temperatures. Finally, the lack of a systematic, constraint based approach to resin design was bridged by using the results of earlier process-structure-property explorations to create an intuitive framework for resin screening and design. Key screening parameters (such as UV absorptivity, plateau storage modulus) and design parameters (such as photoinitiator concentration, polymer concentration, UV blocker concentration) were identified and the methods to optimize them to meet the desired printability metrics were demonstrated using case studies. Most work in vat photopolymerization either deal with materials development or process development and modeling. This dissertation is placed at the intersection of process development and materials development, thus giving it an unique perspective for exploring the inter-dependency of machine and material. The process models, machines and techniques used in this work to make a material printable will serve as a guide for chemists and engineers working on the next generation of vat photopolymerization machines and materials.
Multi-material Additive Manufacturing of Metamaterials with Giant, Tailorable Negative Poisson's Ratios
Chen, Da; Zheng, Xiaoyu (Springer Nature, 2018-06-14)
Nature has evolved with a recurring strategy to achieve unusual mechanical properties through coupling variable elastic moduli from a few GPa to below KPa within a single tissue. The ability to produce multi-material, three-dimensional (3D) micro-architectures with high fidelity incorporating dissimilar components has been a major challenge in man-made materials. Here we show multimodulus metamaterials whose architectural element is comprised of encoded elasticity ranging from rigid to soft. We found that, in contrast to ordinary architected materials whose negative Poisson's ratio is dictated by their geometry, these type of metamaterials are capable of displaying Poisson's ratios from extreme negative to zero, independent of their 3D micro-architecture. The resulting low density metamaterials is capable of achieving functionally graded, distributed strain amplification capabilities within the metamaterial with uniform micro-architectures. Simultaneous tuning of Poisson's ratio and moduli within the 3D multi-materials could open up a broad array of material by design applications ranging from flexible armor, artificial muscles, to actuators and bio-mimetic materials.
A Multi-Material Projection Stereolithography System for Manufacturing Programmable Negative Poissons Ratio Structures
Chen, Da (Virginia Tech, 2017-02-07)
Digital light Projection based Additive Manufacturing (AM) enables fabrication of complex three-dimensional (3D) geometries for applications ranging from rapid prototyping jet parts to scaffolds for cell cultures. Despite the ability in producing complex, three-dimensional architectures, the state of art DLP AM systems is limited to a single homogenous photo-polymer and it requires a large volume of resin bath to begin with. Extensible Multi-material Stereolithography (EMSL) is a novel high-resolution projection stereolithography system capable of manufacturing hybrid 3D objects. This system provides new capabilities, allowing more flexible design criteria through the incorporation of multiple feedstock materials throughout the structure. With EMSL manufacturing ability, multi-material programmable negative Poissons ratio honeycomb reentrant structures are realized. Researchers have been studying auxetic structures over decades, the mechanical property control of auxetic structure mainly relies on geometry design in previous studies. Now with the help of EMSL system, other design variables associated with auxetic structures, such as material properties of local structural members, are added into design process. The additional variables are then proved to have significant effects on the material properties of the auxetic structures. The ability to accurately manufacture multi-material digital design will not only allow for novel mechanical and material researches in laboratory, but also extend the additive manufacturing technology to numerous future applications with characteristics such as multiple electrical, electromechanical and biological properties. The design and optimization of EMSL system realizes novel structures have not been producible, therefore it will stimulate new possibilities for future additive manufacturing development.
A Physical Hash for Preventing and Detecting Cyber-Physical Attacks in Additive Manufacturing Systems
Brandman, Joshua Erich (Virginia Tech, 2017-06-22)
This thesis proposes a new method for detecting malicious cyber-physical attacks on additive manufacturing (AM) systems. The method makes use of a physical hash, which links digital data to the manufactured part via a disconnected side-channel measurement system. The disconnection ensures that if the network and/or AM system become compromised, the manufacturer can still rely on the measurement system for attack detection. The physical hash takes the form of a QR code that contains a hash string of the nominal process parameters and toolpath. It is manufactured alongside the original geometry for the measurement system to scan and compare to the readings from its sensor suite. By taking measurements in situ, the measurement system can detect in real-time if the part being manufactured matches the designer's specification. A proof-of-concept validation was realized on a material extrusion machine. The implementation was successful and demonstrated the ability of this method to detect the existence (and absence) of malicious attacks on both process parameters and the toolpath. A case study for detecting changes to the toolpath is also presented, which uses a simple measurement of how long each layer takes to build. Given benchmark readings from a 30x30 mm square layer created on a material extrusion system, several modifications were able to be detected. The machine's repeatability and measurement technique's accuracy resulted in the detection of a 1 mm internal void, a 2 mm scaling attack, and a 1 mm skewing attack. Additionally, for a short to moderate length build of an impeller model, it was possible to detect a 0.25 mm change in the fin base thickness. A second case study is also presented wherein dogbone tensile test coupons were manufactured on a material extrusion system at different extrusion temperatures. This process parameter is an example of a setting that can be maliciously modified and have an effect on the final part strength without the operator's knowledge. The performance characteristics (Young's modulus and maximum stress) were determined to be statistically different at different extrusion temperatures (235 and 270 °C).
Reconfigurable Intelligent Metasurfaces for Wireless Communication and Sensing Applications
Hodge II, John Adams (Virginia Tech, 2022-01-05)
In recent years, metasurfaces have shown promising abilities to control and manipulate electromagnetic (EM) waves through modified surface boundary conditions. These surfaces are electrically thin and comprise an array of spatially varying sub-wavelength scattering elements (or meta-atoms). Metasurfaces can transform an incident EM wave into an arbitrarily tailored transmitted or reflected wavefront through carefully engineering each meta-atom. Recent developments in metasurfaces have opened exciting new opportunities in antenna design, sensing, and communications systems. In particular, reconfigurable metasurfaces - wherein meta-atoms are embedded with active components - lead to the development of low-cost, lightweight, and compact systems capable of producing programmable radiation patterns and jointly performing multi-function communications, and enable advanced sensors for next-generation platforms. This research introduces reconfigurable metasurfaces and their various applications in designing simplified communications systems, wherein the RF aperture and transceiver are integrated within the metasurface. Finally, we will present our recent work on reconfigurable metasurfaces control, metasurface-enabled direct signal modulation, and deep learning-based metasurface design.

Browsing by Author "Zheng, Xiaoyu"

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