Simulating fluidically shaped geometries
OA Version
Citation
Abstract
In the realm of design, there is an emerging capability in which algorithms are used to create elaborate geometries, which are not only aesthetically pleasing but also mechanically functional. However, these shapes are inherently difficult to realize, so a proposed manufacturing method to address this challenge is Fluidic Shaping. In this method, a liquid polymer is deployed onto a custom wire frame structure, then solidified. This process is done in an immersion liquid whose density matches that of the polymer. As a result, the effect of gravity is removed, leaving surface tension as the only net force driving the system to its minimum-energy configuration. Once the intended geometry is achieved, the newly obtained part is removed from the immersion liquid, ready for use. The objective of this thesis is to simulate the behavior of a liquid polymer when deployed onto a given wire frame, thus predicting its final shape. These simulations allow for verifying a proposed geometry prior to conducting experiments, saving time and resources. We developed and simulated a set of “primitives,” simple shapes which exhibit elementary liquid behavior, such that complex geometries can be modeled by superposing these shapes. We used two simulation approaches: (1) an existing finite element approximation and (2) direct theoretical modeling, in which we numerically solved the applicable governing equation. We discuss the advantages and disadvantages of each approach, comparing the results from the former method to experiments conducted in the lab. The simulations from the finite element approximation are quantitativelyclose to the experiments. Lastly, we show results for the latter method, including an example structure fabricated using primitives.
Description
2026
License
Attribution-NonCommercial 4.0 International