Manufacturing Complex Structures Through Interfacial Self- Organization
Events | Mechanical Engineering
Manufacturing Complex Structures Through Interfacial Self- Organization
Conventional manufacturing approaches rely on the explicit shaping, deposition, or removal of material to produce a desired geometry. But what if, instead of directly prescribing every geometric feature, we could make materials organize themselves into the desired shape? In this talk, I will introduce Fluidic Shaping, a manufacturing approach that exploits surface tension and interfacial energy minimization to shape liquid polymers into complex three-dimensional objects. The talk will be divided into two parts. First, I will describe how Fluidic Shaping was originally developed for the fabrication of optical components. By manipulating liquid interfaces under simulated microgravity conditions, we can produce high-quality optical surfaces with nanometric smoothness, without mechanical polishing or elaborate manufacturing infrastructure. I will discuss the underlying physical principles, experimental demonstrations, and our collaboration with NASA on the development of a fluidic telescope in space. In the second part, I will present our recent efforts to generalize Fluidic Shaping beyond optics, toward the fabrication of complex three-dimensional structures. By combining computational geometry with interfacial self-organization, we have developed a framework that decomposes arbitrary target geometries into constant- mean-curvature surfaces, whose boundaries define sparse wireframe scaffolds the encode the target geometry. When liquid polymers are introduced into these scaffolds, capillary forces drive the liquid towards the desired shape, which can then be solidified into a functional structure. I will present recent experimental demonstrations, including fabrication of topology-optimized structures and multi-material components, and discuss the opportunities this approach creates for manufacturing geometries that are difficult to realize using conventional techniques.