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Rapid and Low-cost Prototyping of Medical Devices Using 3D Printed Molds for Liquid Injection Molding

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Published on: June 27, 2014

Design of Revolute Joints for In-Mold Assembly Using Insert Molding.

Arvind Ananthanarayanan¹, Leicester Ehrlich, Jaydev P Desai

¹Biomimetics Robotics Laboratory, Massachussetts Institute of Technology, Cambridge, MA 02140 ,

Journal of Mechanical Design (New York, N.Y. : 1990)

|August 2, 2013

Summary

This summary is machine-generated.

Insert molding can create complex articulated structures in one step by embedding metallic bearings in plastic. This study models joint jamming caused by polymer shrinkage, enabling optimized designs for functional, multi-degree-of-freedom assemblies.

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Area of Science:

Mechanical Engineering
Materials Science
Robotics

Background:

Manufacturing highly articulated miniature structures is complex and costly due to multi-part assembly.
Insert molding offers a potential single-step solution for creating articulated structures by co-molding metallic bearings with polymers.
Polymer shrinkage during insert molding typically causes joint jamming, hindering the creation of functional articulated components.

Purpose of the Study:

To develop a theoretical model for quantifying joint jamming in insert-molded articulated structures.
To identify optimal design parameters for fabricating functional, multi-degree-of-freedom assemblies using insert molding.
To overcome limitations of current insert molding techniques for creating articulated components.

Main Methods:

Development of a theoretical model to estimate joint jamming torque caused by polymer shrinkage on metallic bearings.
Utilizing the model to determine optimal design parameters considering manufacturing constraints.
Experimental fabrication and validation of insert-molded articulated structures.

Main Results:

The theoretical model accurately predicts joint jamming, enabling the selection of optimal design parameters.
Weld-line strength significantly influences the minimum joint dimensions required for functional revolute joints.
Successful fabrication of a multi-degree-of-freedom articulated structure for a medical robot prototype.

Conclusions:

Insert molding can be effectively utilized to produce highly articulated structures in a single step.
The developed theoretical model provides a pathway to design functional insert-molded articulated components.
This research demonstrates the first successful application of insert molding for creating multi-degree-of-freedom articulated structures, with potential in medical robotics.