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A Holistic Approach to Design for 4D Printing

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A Holistic Approach to Design for 4D Printing THESE DE DOCTORAT DE L’ETABLISSEMENT UNIVERSITE BOURGOGNE FRANCHE-COMTE PREPARÉE À L’UNIVERSITÉ DE TECHNOLOGIE DE BELFORT-MONTBÉLIARD (UTBM) Ecole doctorale n°37 SPIM – Sciences Physiques pour l’Ingénieur et Microtechniques Doctorat de Mécanique Par M. SOSSOU Germain Une approche globale de la conception pour l'impression 4D Thèse présentée et soutenue à Sevenans, le 12 février 2019 Composition du Jury : M. ANDRÉ Jean-Claude Directeur de Recherche CNRS - Président Université de Lorraine M. BRISSAUD Daniel Professeur d’université – Institut Rapporteur National Polytechnique de Grenoble M. BERNARD Alain Professeur d’université – École Rapporteur Centrale de Nantes M. QI H. Jerry (en visioconférence) Professeur d’université – Georgia Examinateur Institute of Technology M. GOMES Samuel Professeur d’université – Université Directeur de thèse de Technologie de Belfort Montbéliard M. MONTAVON Ghislain Professeur d’université – Université Co-directeur de thèse de Technologie de Belfort Montbéliard M. DEMOLY Frédéric Maître de Conférences HDR – Encadrant de thèse Université de Technologie de Belfort Montbéliard Résumé Titre : Une approche globale de la conception pour l'impression 4D Mots clés : Fabrication additive ; Conception pour la fabrication additive ; matériaux intelligents ; Impression 4D ; Conception pour l’impression 4D ; Modélisation à base de voxels ; Conception avec les matériaux intelligents. Résumé : Inventée en 1983, comme procédé matériaux, caractérisation, etc.). Cependant très de prototypage rapide, la fabrication additive peu de travaux sont entrepris pour (FA) est aujourd’hui considérée comme un accompagner les concepteurs (qui, a priori, ne procédé de fabrication quasiment au même titre sont ni experts FA ni des experts de MIs) à que les procédés conventionnels. On trouve par l’utiliser dans leurs concepts. Cette nouvelle exemple des pièces obtenues par FA dans des interaction procédé-matériau requiert en effet structures d’aéronef. Cette évolution de la FA des modèles, des méthodologies et outils de est due principalement à la liberté de forme conception adaptés. Cette thèse sur la permise par le procédé. Le développement de conception pour l’impression 4D a pour but de diverses techniques sur le principe de combler ce vide méthodologique. Une fabrication couche par couche et l’amélioration méthodologie de conception pour la FA a été en quantité et en qualité de la palette de proposée. Cette méthodologie intègre les matériaux pouvant ainsi être mis en forme, ont libertés (forme, matériaux, etc.) et les été les moteurs de cette évolution. De contraintes (support, résolution, etc.) nombreuses autres techniques et matériaux de spécifiques à la FA et permet aussi bien la FA continuent de voir le jour. Dans le sillage conception de pièces que celle d’assemblages. de la FA (communément appelée impression En particulier, la liberté de forme a été prise en 3D) a émergé un autre mode de fabrication : compte en permettant la génération d’une l’impression 4D (I4D). L’I4D consiste à géométrie minimaliste basée sur les flux explorer l’interaction matériaux intelligents fonctionnels (matière, énergie, signal) de la (MIs) – FA. Les MIs sont des matériaux dont pièce. Par ailleurs, les contributions de cette l’état change en fonction d’un stimulus ; c’est thèse ont porté sur la conception avec les le cas par exemple des matériaux matériaux intelligents. Parce que les MIs jouent thermochromiques dont la couleur change en plus un rôle fonctionnel que structurel, les réponse à la chaleur ou des hydrogels qui préoccupations portant sur ces matériaux peuvent se contracter en fonction du pH d’un doivent être menées en amont du processus de milieu aqueux ou de la lumière. Les objets ainsi conception. En outre, contrairement aux obtenus ont – en plus d’une forme initiale (3D) matériaux conventionnels (pour lesquels – la capacité de changer d’état (en fonction des quelques valeurs de paramètres peuvent suffire stimuli auxquels sont sensibles les MIs dont ils comme information au concepteur), les MIs sont faits) d’où la 4e dimension (temps). L’I4D requièrent d’être décrits plus en détails fait – à juste titre – l’objet d’intenses (stimulus, réponse, fonctions, etc.). Pour ces recherches concernant l’aspect fabrication raisons un système d’informations orientées (exploration de nouveaux procédés et conception sur les MIs a été mis au point. i Université Bourgogne Franche-Comté 32, avenue de l’Observatoire 25000 Besançon Ce système permet, entre autre, d’informer les permet également le calcul d’une distribution concepteurs sur les capacités des MIs et aussi fonctionnelle de MIs et matériau conventionnel de déterminer des MIs candidats pour un ; distribution qui, compte tenu d’un stimulus, concept. Le système a été matérialisé par une permet de déformer une forme initiale vers une application web. Enfin un cadre de forme finale désirée. Un outil – construit dans modélisation permettant de modéliser et de l’environnement Grasshopper, un plug-in du simuler rapidement un objet fait de MIs a été logiciel de CAO Rhinoceros® – matérialisant proposé. Ce cadre est basé sur la modélisation ce cadre méthodologique a également été par voxel (pixel volumique). En plus de la développé. simulation des MIs, le cadre théorique proposé . ii Université Bourgogne Franche-Comté 32, avenue de l’Observatoire 25000 Besançon Abstract Title: A holistic approach to design for 4D Printing Keywords: Additive manufacturing; Design For Additive Manufacturing (DFAM); Smart materials; 4D printing, Design for 4D Printing (DF4DP); Voxel-based modeling; Design with Smart Materials (DwSMs). Abstract: Invented in 1983, as a rapid designers (who, in principle, are neither AM prototyping process, additive manufacturing experts nor experts of SMs) to use it in their (AM) is nowadays considered as a concepts. This new process-material interaction manufacturing process almost in the same way requires adapted models, methodologies and as conventional processes. For example, parts tools in design. This PhD on design for 4D obtained by AM are found in aircraft printing aims at filling this methodological gap. structures. This AM evolution is mainly due to A design methodology for AM (DFAM) has the shape complexity allowed by the process. been proposed. This methodology integrates The driving forces behind this evolution the freedoms (shape, materials, etc.) and the include: the development of various techniques constraints (support, resolution, etc.) peculiar to on the layer-wise manufacturing principle and the AM and allows both the design of parts and the improvement both in quantity and quality assemblies. Particularly, freedom of form has of the range of materials that can be processed. been taken into account by allowing the Many other AM techniques and materials generation of a minimalist geometry based on continue to emerge significantly. In the wake the functional flows (material, energy, and of the AM (usually referred to as 3D printing) signal) of the part. This methodology integrates another mode of manufacturing did emerge: 4D the freedoms (shape, materials, etc.) and the printing (4DP). 4DP consists in exploring the constraints (support, resolution, etc.) peculiar to smart materials (SM) – AM interaction. SMs the AM and allows both the design of parts and are materials whose state changes according to assemblies. Particularly, freedom of form has a stimulus. This is the case, for example, with been taken into account by allowing the thermochromic materials whose color changes generation of a minimalist geometry based on in response to heat or hydrogels which can the functional flows (material, energy, and shrink as a function of an aqueous medium’s signal) of the part. In addition, the pH or of light. The objects thus obtained have – contributions of this PhD focused on designing in addition to an initial form (3D) – the with smart materials (DwSM). Because SMs capacity to shift state (according to the stimuli play a functional rather than a structural role, the SMs making them are sensitive to) hence concerns about these materials need to be the 4th dimension (time). 4DP is – rightly – the addressed in advance of the design process subject of intense research concerning the (typically in conceptual design phase). In manufacturing aspects (exploration of new addition, unlike conventional materials (for processes and materials, characterization, etc.). which a few parameter values may suffice as However, very little work is done to support information to the designer), SMs need to be iii Université Bourgogne Franche-Comté 32, avenue de l’Observatoire 25000 Besançon described in more detail (stimulus, response, This framework is based on voxel (volumetric functions, etc.). For these reasons, a design- pixel) modeling. In addition to the simulation oriented database (including a design decision of SMs behaviors, the proposed theoretical support) on SMs has been developed. This framework also allows the computation of a system makes it possible, among other things, functional distribution of SMs and to inform designers about the capabilities of conventional material; distribution which, SMs and also to determine SMs candidates for given a stimulus, makes it possible to deform a concept. The system has been developed as a an initial form towards a desired final form. A Web-service application. Finally, a modeling tool – based on the Grasshopper environment, a framework allowing quickly modeling and plug-in of the CAD software Rhinoceros® – simulating an object made of
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