Multiple Material Topology Optimization of Compliant Mechanisms Created Via PolyJet Three Dimensional Printing

Abstract

Compliant mechanisms are able to transfer motion, force, and energy using a monolithic structure without discrete hinge elements. The geometric design freedoms and multimaterial capability offered by the PolyJet 3D printing process enables the fabrication of compliant mechanisms with optimized topology. The inclusion of multiple materials in the topology optimization process has the potential to eliminate the narrow, weak, hingelike sections that are often present in singlematerial compliant mechanisms and also allow for greater magnitude deflections. In this paper, the authors propose a design and fabrication process for the realization of 3phase, multiplematerial compliant mechanisms. The process is tested on a 2D compliant force inverter. Experimental and numerical performance of the resulting 3phase inverter is compared against a standard 2phase design.