* Graduate Student, IEEE Student Member. Rapid Prototyping of Robotic Systems. 98 Brett Rd, Piscataway, NJ,

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1 Proceedinps of the 2000 IEEE lntemahonal Conference on Robotics & Automation San Francisco. CA April 2000 Rapid Prototyping of Robotic Systems Jey Won', Kathryn DeLaurentis2 and Constantinos Mavroidis3 Robotics and Mechatronics Laboratory Department of Mechanical and Aerospace Engineering Rutgers University, The State University of New Jersey 98 Brett Rd, Piscataway, NJ, Tel: , Fax: jwon@eden.rutgers.edu, kjdela@jove.rutgers.edu, mavro@jove.rutgers.edu Abstract In this paper, the application of Rapid Prototvping in fabricating non-assembly robotic systems is presented. Using the Stereolithography Apparatus SLA 190 of the Department of Mechanical and Aerospace Engineering of Rutgers University, and the Selective La5 er Sintering Sinterstation 2000 of DTM Corporation of Austin, TX, prototvpes of mechanical joints were fabricated experimentalb. The designs of these component joints were then used to fabricate the articulated structure of experimental prototypes for two robotic systems: I) a three-legged parallel manipulator; 2) a four degree of9eedomfinger of a five-fingered robotic hand. 1 Introduction It is always desirable to evaluate a proposed robot design prior to full prototyping to ensure the swiftest and most cost effective design changes. Even though powerful three dimensional Computer Aided Design and Dynamic Analysis software packages such as PreEnginea-, IDEAS, ADAMS and Working Model 3-D are now being used, they can not provide important visual, haptic and realistic workspace information for the proposed design. In addition, there is a great need for developing methodologies and techniques that will allow fast design, fabrication and testing of robtic systems. A framework for the feasibility and usefulness of applying Rapid Prototyping in fabricating robotic systems is presented here. Rapid prototyping of parts and tools is a rapidly developing technology [l, 21 with many advantages: a) time and money savings, b) quick product testing, c) expeditious design improvements, d) fast error elimination 6-om design e) increased product sales, and t) rapid manufacturing. Its main advantage is early verification of product designs. Rapid Prototyping is quickly becoming a valuable key for efficient and concurrent engineering. Through different techniques, engineers and designers are now able to bring a new product from concept modeling to part testing in a matter of weeks or months. In some instances, actual part production may even be possible in very short time. Rapid Prototyping has indeed simplified the task of describing a concept to design teams, illustrating details to engineering groups, specifjmg parts to purchasing departments, and selling the product to customers. Robotic systems have been used as part of a rapid prototyping process [3,4]. However, the application of Rapid Prototyping in robot design and fabrication has been very limited. One of the first works to rapidly fabricate robotic systems was made by Professor Gosselin and his group at Lava1 University who used a Fused Deposition Modeling Rapid Prototyping machine [5]. Several mechanisms were fabricated such as a six-legged six degreeof-freedom parallel manipulator. These rapidly manufactured mechanisms re quired assembly afier Rapid Prototyping of the mechanism parts. Recently, our group at Rutgers University has fabricated a three-legged, six degree-of-freedom Rapid Prototype of a parallel manipulator in one step, without requiring assembly [6]. To do this, a set of joints that includes revolute, prismatic, universal and spherical joints, was fabricated using the Stereolithography machine model SLA 190, fiom 3D Systems, CA. Each leg of the three-legged platform was composed of two spherical and one prismatic joint and was connecting two triangular links. To the authors' knowledge, this is the first successful fabrication of a multi-joint, multi degree of-fieedom robotic system that was Rapidly Prototyped without requiring any assembly. The use of Rapid Prototyping in the fabrication of nonassembly type robotic systems is firther explored in this pa- Undergraduate Research Assistant, IEEE Student Member * Graduate Student, IEEE Student Member Assistant Professor, IEEE Member, Corresponding Author /00/$ l O.OO@ 2000 IEEE 3077

2 per. The main focus of this investigation is the successfil design and construction of articulated structures using another prototyping technique known as Selective Laser Sintering (SLS). Prototype joints similar to those fabricated with the Stereolithography process, are Rapidly Prototyped using the Selective Laser Sintering Sinterstation 2000 of DTM Corporation of Austin, TX. in addition, one four degree of 6dom finger of a robotic hand with four fingers, a thumb and a palm is constructed as one non-assembly type mechanism. Rapid actuation of the joints of the rapidly prototyped systems is outside the scope of this paper and will be studied in our fb ture work. 2 Rapid Prototyping Rapid Prototyping or Layered Manufacturing is a fabrication technique where 3-dimensional solid models are constructed layer upon layer by the hion of material under computer control. This process genmlly consists of a substance, such as fluids, waxes, powders or laminates, which serves as the basis for model construction as well as sophisticated computer-automated equipment to control the processing techniques such as deposition, sintering, lasing, etc [7, 81. Also refmed to as Solid Freeform Fabrication, Rapid Prototyping complements existing conventional manufacturing methods of material removing and forming. It is widely used for the rapid fabrication of physical prototypes of functional parts, patterns for molds, medical prototypes such as implants, bones and consumer products [9]. Its main advantage is early verification of product designs. Through quick design and error elimination, Rapidly Prototyped parts show great cost savings over traditionally prototyped parts in the total product life cycle [IO]. Currently, there are over 30 different types of Rapid Prototyping processes in existence. Some of these techniques are commercially available while others are still in development in research laboratories [IO]. Over the years, major improvements in the overall quality of prototyped parts have been achieved through enhancements in accuracy, material choice and durability, part throughput, surface texture, and altemative RP processes. These improvements have led to an evolution of the functionality of RP prototypes [S, 91. Evolution of the techniques and applications of Rapid Prototyping is a continually developing and expanding field. Current research is leading to a more functional rapidly prototyped part with an increasing number of applications and part feature enhancements. In this work, two Rapid Prototypes techniques are used: the Stereolithography (SL) and the Selective Laser Sintering (SLS). 2.1 Stereolithography Stereolithography (SL) is a 3-dimensional building process which produces a solid plastic model. In this pro- cess, an ultraviolet (UV) laser traces 2-dimensional crosssections on the surface of a photosensitive liquid plastic (resin). The laser partially cures the resin throu& low energy absorption of laser light thus producing a solid. The first cross-sectional slice is built on a depthcontrolled platform, which is fully submerged under the first thin layer of resin. This and each successive thin layer of liquid resin has a depth equal to that of the vertical slice thickness of the part. After each slice is traced on the surface of resin, the platform lowers by a depth equal to that of the slice thickness. Successive 2-D slices are cured directly onto previous layer as the part is built 60m bottom to top. Support structures are needed to maintain the structural integrity of the part as well as give a starting point and support for overhangs for layers to be built on. These supports are constructed fiom a fine lattice structure of cured resin. After the part is fully built, the support structures are removed and the part is cleaned in a bath of solvent and dried. The prepared parts are then flooded with high-intensity UV light in a Post-Cure Apparatus (PCA) to hlly cure the resin. The Department of Mechanical and Aerospace Engineering of Rutgers IJniversity is equipped with a Stereolithography 190 of 3D Systems, CA. Available basis materials include photopolymer resin epoxies with various physical properties. 2.2 Selective Laser Sintering Selective Laser Sintering (SLS) is a 3-dimensional building process based on the sintering of a metallic or non-metallic powder by a laser. The SLS process involves the heating of the powder using a CO, localized laser beam. This localized heating raises the temperature of the powder enough to cause solidification by fbsion without melting. The model is built on a platform that is situated within a horizontal platen. The platform, which is initially flush with the platen, is lowered a depth equal to that of the slice thickness. A powder is then rolled, scraped or slot-fed onto the platform and then the laser draws the 2- dimensional cross-section. This lowering, powdering and lasing process is repeated until the part is complete. No support structures are necessary in this process since the part rests on and within the non-sintered powder. Post-curing is not necessary except in the case of ceramic parts. Available materials include polycarbonates, nylons, polyamides, elastomers, sand casting materials and steels. The fabrication of prototype parts used in the present investigations was through a professional Rapid Prototyping service provider for SLS manufacturing. The machine used is the Selective Laser Sintering Sinterstation ;!OOO of DTM Corporation of Austin, TX

3 ~ ~ ~~~ ~~ 3 Joint Fabrication 3.1 SL Fabricated Joints The first step in building robotic systems with a Rapid Prototyping machine is to be able to successfully fabricate joints. Different types of mechanical joints such as revolute, prismatic, universal and spherical joints were fabricated with the SLA machine of the Department of Mechanical and Aerospace Engineering (Figure 1). These joints were produced without requiring assembly. Through a trial and error process, different features such as clearance, part size and support structure generation were optimized to produce working mechanical joints. Of these features, determination of clearances was very important in successful part fabrication. The optimum clearances between two near surfaces, were determined to be 0.3 mm for flat surfaces and 0.5 mm for circular surfaces. Also, the size of these parts is in the order of a few centimeters. This was done to determine the limits of the available apparatus as well as to conserve processing time and material. The universal joint design was that of a classical cross-type assembly which consisted of two different constitutive components; the two yokes and the connecting cross hub. One of the two initial universal joint designs is shown in Figure 3. Using design reference to the revolute joint, the universal joint was also fabricated using the 0.5 mm circular surface clearance. This joint was fabricated in the upright position along its length and a picture of the prototype is shown in Figure 1. The completion of this build cycle took approximately 5 hours. FIGURE 2. CAD Drawing of a Prismatic Joint. FIGURE 1. Stereolithography Joint Fabrications The revolute and spherical joints have been described in [6]. Here, we present briefly the prismatic and universal joint. Initially, the prismatic joint or sliding joint was characterized by that of a piston-cylinder type assembly. Poor sliding of the joint resulted from a volume of trapped resin in the chamber that could not be effectively or easily removed prior to final ultra-violet curing. Also evident in the joint assembly was the presence of an undesired additional degrees of freedom. The joint was then redesigned with these two factors as limiting constraints. The fhai design of the joint is shown in Figure 2. This one degreeof-freedom sliding joint did not have any closed cavities of resin. Also, the rectangular shape entirely avoided the SLA machine software s linear approximation of curved lines resulting in closer clearancing of parts. This joint was fabricated in the upright position along its length and is shown in Figure 1. The completion of this build cycle took approximately 6 hours. FIGURE 3. CAD Drawing of a Universal Joint When building joints at an oblique configuration, instead of a vertical one (upright configuration), a special effect appears called the step effect or staircase effect. This effect can reduce the quality of fabrication of the joint. This is the result of approximating a continuous curved surface in the vertical direction with a discrete set of horizontal thin layers. Obviously, the thinner the layer or building the part in an orientation closer to a vertical configuration reduces this effect. 3.2 SLS Fabricated Joints Joints of robotic systems were also built using the Selective Laser Sintering (SLS) Sinterstation 2000 of DTM Corporation of Austin, TX. The basis material chosen was a polyamide. Clearances similar to that established for joints fabricated using the Stereolithography SLA 190 process were used as trial values. These values are conservative as the Sinterstation 2000 has a greater

4 level of accuracy, versus k0.0075, and a smaller layer thickness, versus 0.006, over that of the SLA 190. The thinner layers reduce the staircase effect in rounded joints. Two different types of joints were fabricated with the SLS machine: a revolute joint and a spherical joint. Both joints are parts of a rapid prototyped robotic hand that is presented in Section 4.2. Because of their use in a robotic hand the joints needed to satis@ specific design criteria. The revolute joint connecting the ends of two links, was to be restricted to approximately 100 of revolution. This limitation on the range of motion was accomplished through the rounding of one side of the yoke section of the fixed link side. As can be seen in Figure 4, this rounding allows the links to clear each other in revolution only through the desired range of motion. r Ph 1 FIGURE 4. Revolute Joint The spherical joint, which serves as the knuckle at the finger-palm intdce (see Figure lo), is to have approximately 90 of revolution and about 515 of side-t* side fieedom in the klly extended configuration and 0 of side-teside fieedom in the fully contracted configuration. This is a rough approximation on the range of motion present in an average human finger. The limitation on spherical range of motion was achieved by slotting the socket section in a shape as seen in Figure 5. Another restriction was that of minimizing the range of twist about the extended-finger axis. This was accomplished by removing material fiom diametrical hemispheres of the inner ball and adding material to the inner section of the socket resulting in a modified spherical joint (Figure 6). The combination of the modified ball and the slotted socket will not fully restrict but will serve to limit the range of twist to approximately +lo ; a value atxeptable in preliminary prototypes. As seen in Figure 7, using the SLS process to build non-assembly type joints proved successful. Both parts exhibited good mobility through the desired ranges of motion. Also, the presence of the staircase effect was reduced due to the Shterstation process thin layer thickness. The fabrication of these two joints was the first verification step in the robotic hand construction. The improvement in rounded s hce quality has important consequences in the design of these joints. First, the decreased step effect means that the clearances between moving surfaces can be reduced to a lower value. Another important effect is the diminished importance of part orientation during the fabrication process in roimded as well as in flat and sloped components. Selective Laser Sintered parts do not require any computer or manually generated support structures. This is an important process advantage. Parts do not have to be designed wiih the thought of support structures placement in part orientation during the build cycle as well as performing the task of support removal. FIGURE 6. Modified Spherical uknuckle Joint FIGURE 5. View of Modified Socket FIGURE 7. SLS Fabricated Joints 3080

5 4 Robot Fabrication 4.1 Parallel Manipulators A threelegged 6-DOF parallel manipulator was &osen as the first mechanism to be hbricated with the Stereolithe graphy SLA 190. First, one leg of the parallel manipulator was built to demonstrate the feasibility. The leg of the parallel manipulator consists of two spherical joints, one at ea& end, and a prismatic joint at the middle of the leg. The designs of the joints presented in Section 3.1 were used. The hbricated legs are shown in Figure 8. The 6nal platform was built with three identical legs. The top and bottom platforms are two triangular ternary links (links cormected to three joints) having the same dimensions of 1 "xl "x 1 " on three sides of the triangle and the thickness was "(2 mm). To save fabrication time, the triangular platforms were not completely filled- Since the fabrication of each joint was tested separately, the fabrication of the leg was hvorably completed. In Figure 9, pictures of the hbricated rapid protolype of the parallel manipulator are shown in two different amfigurations. This prototype was built overnight during a 12-hour period. FIGURE a A Leg of the Parallel Manipulator of three cylindrical links connected by two revolute joints (Figure 11). Each of the fingers is to be attached to the palm section by spherical joints. FIGURE 10. CAD Rendering of Robotic Hand Rapid Actuation of the robotic hand is to be achieved through a combination of cables and Shape Memory AIloy artificial muscle wires. Shape Memory Alloy (Sm) wires are characterized by a reduction in length when resistive heat is generated through the length of the wire by the flow of electricity. The SMA wires to be used in this design have a wire diameter of approximately 0.5 mm (0.02") and are available in continuous spools. The cables will be connected close to the pivot points of the revolute joints and will run through the incorporated "pathways" within the length of the fingers. The cables will be crimped to SMA muscle wires proximal to the palm. It is necessary to run the cables through the hand rather than the SMAs themselves as the activation temperature of the SMA is C and the melting temperature of the SL material is 85 C. (The melting temperature is not a consideration with the SLS material as its melting temperature is 185OC.) The use of SMA wires will be the first attempt at actuating a Rapidly Prototyped system at Rutgers University. FIGURE 9. Three Legged Parallel Manipulator 4.2 Robotic Hand Another complex system that is currently being designed and fabricated is that of a robotic hand with five fingers and a palm; all constructed as one non-assembly type mechanism (Figure 10). This robotic hand is designed with the fbture purpose of using a Rapidly F'rototyped robotic hand as a possible replacement for mechanically driven prosthetic hands. The fingers are composed FIGURE 11. A Robotic Finger 308 1

6 Another important design consideration in this robotic hand prototype is to be able to have the same range of motion and be similar in sue to that of an average human hand. The former guiding design feature necessitated the use of modified joint designs to partially restrict some of the degrees-of-fieedom. The design features and fabrication of these joints was presented in Section 3.2. Presently, a single robotic finger has been fabricated using the SLS process as shown in Figure 12. The SLS procedure here was similar to that of the revolute and spherical joints described in 3.2. The SLS process produced a quality, fully assembled finger with good joint mobility, clearances, and ranges of motion. The SLS glass filled nylon material used for this assembly provided for less joint fiiction than the previously polyamide fabricated single joints. The clearances are such that there is some additional movement in the joints than desired, so it would be possible to reduce these tolerances in the future. As in the previous SLS constructions, the joints fully reach the designed range of motion. Additionally, all the pathways and cable assembly holes were clear of material. The Selective Laser Sintering process successfully fabricated this multi-joint, multi-degree-of-fkdedom robotic finger. FIGURE 12. Robotic Finger Built With SLS 6 Conclusions Rapid Prototyping has been shown to be a viable means of simple and quick fabrication of prototypes for the articulated structures of robotic systems. Several joints and robotic systems have been fabricated using this framework. The successful fabrication of the robotic hand gives further confidence in this Rapid Prototyping h e - work. In the future, actuation of rapidly fabricated prote types will be investigated through the use of Shape Memory Alloy artificial muscles or other types of smart materials. 7 Acknowledgments This work has been supported by the Center for Computational Design of Rutgers University, The Center for Advanced Information Processing (CAIP), and the NASA Space Grant Consortium. References Ashley S., 1995, " Rapid Prototyping is Coming of Age", Mechanical Engineering, Vol. 117, No. 7, pp Ashley S., 1998, "RP Industry's Growing Pains," Mechanical Engineering, Vol. 120, No. 7, pp Tse W. C. and Chen Y. H., 1997, "A Robotic Systems for Rapid Prototyping," Proc. of the 1997 IEEE International Coqerence on Robotics and Automation, Albuquerque, NM, pp Vergeest J. and Tangelder W., 1996, "Robot Machines Rapid Prototype," Industrial Robot, Vol. 23, NO. 5, pp Laliberte T., Gosselin C. and Cote G., 1999, "Rapid Prototyping of Mechanisms", Proceedings of the Id World Congress on the Theory of Machines and Mechanisms, Oulu, Finland. Alam M., Mavroidis C., Langrana N. and Bidaud P., 1999, "Mechanism Design using Rapid Prototyping", Proceedings of the World Congress on the Theory of Machines and Mechanisms, Oulu, Finland. Dolenc A., "An Overview of Rapid Prototyping Technologies in Manufacturing", Helsinki [Jniv. of Technology, Cradord R. and Beaman J., 1999, "Solid Freeform Fabrication: A New Manufacturing Paradigm," LEEE Spectrum, February 1999, pp Bylinsky G., "Industry's Amazing Instant Prototypes", Fortune, Vol. 137No. 1, [ 101 Wohlers T., Rapid Prototyping and Tooling State of the Industiy: 1999 Worldwide Progress Report, Wohlers Associates,