Mesoscale fabrication and design

A strong link between mechanical engineering design and materials science and engineering fabrication can facilitate an effective and adaptable prototyping process. In this dissertation, new developments in the lost mold-rapid infiltration forming (LM-RIF) process is presented which demonstrates the relationship between these two fields of engineering in the context of two device applications. Within the LM-RIF process, changes in materials processing and mechanical design are updated iteratively, often aided by statistical design of experiments (DOE).;The LM-RIF process was originally developed by Antolino and Hayes et al to fabricate mesoscale components. In this dissertation the focus is on advancements in the process and underlying science. The presented advancements to the LM-RIF process include an augmented lithography procedure, the incorporation of engineered aqueous and non-aqueous colloidal suspensions, an assessment of constrained drying forces during LM-RIF processing, mechanical property evaluation, and finally prototype testing and validation. Specifically, the molding procedure within the LM-RIF process is capable of producing molds with thickness upwards of 1mm, as well as multi-layering to create three dimensional structures. Increasing the mold thickness leads to an increase in the smallest feature resolvable; however, the increase in mold thickness and three dimensional capability has expanded the mechanical design space.;Tetragonally stabilized zirconia (3Y-TZP) is an ideal material for mesoscale instruments, as it is biocompatible, exhibits high strength, and is chemically stable. In this work, aqueous colloidal suspensions were formulated with two new gel-binder systems, increasing final natural orifice translumenal endoscopic surgery (NOTES) instrument yield from 0% to upwards of 40% in the best case scenario. The effects of the gel-binder system on the rheological behavior of the suspension along with the thermal characteristics of the gel-binder system were characterized. Finally, mechanical properties of ceramic specimens were obtained via 3-point bend testing.;Another candidate material for NOTES devices as well as cellular contact aided compliant mechanisms (C3M) devices is 300 series stainless steel (300 series stainless steel). 300 series stainless steel is a common biocompatible material; it is used in surgical applications, exhibits a high corrosion resistance, and has high strength to failure. New, high solids loading, non-aqueous colloidal suspensions of 300 series stainless steel were formulated and incorporated into the LM-RIF process. The rheological behavior and thermal characteristics of the non-aqueous colloidal suspensions were analyzed and engineered to operate within the LM-RIF process. Final part yield with the non-aqueous colloidal suspensions was higher than that of the aqueous ceramic suspensions. Mechanical properties of 300 series stainless steel specimens were determined via 3-point bend testing.;Furthermore, new composite non-aqueous colloidal suspensions of 3Y-TZP and 300 series stainless steel were formulated and incorporated into the LM-RIF process. The composite materials showed an increase in final part yield, and an increase in yield strength compared to pure 300 series stainless steel was determined by Vickers hardness testing. The successful incorporation of composite suspensions in the LM-RIF process was facilitated through an analysis of the rheological behavior as a function of solids loading and ceramic to metal ratio.;Optimized designs of NOTES instruments, as well as C3M devices were manufactured using the LM-RIF process with the non-aqueous 300 series stainless steel suspension. The performance of the prototype NOTES instruments was evaluated and compared against the theoretically predicted performance results, showing good agreement. Similarly, good agreement was seen between the stress-displacement behavior of prototype C3M devices when compared to the theoretically calculated stress-displacement results. Finally, in a comparison by endoscopic surgeons at Hershey Medical Center between an existing industry standard endoscopic device and the mesoscale instrument prototypes fabricated via the LM-RIF process, the prototype design performed favorably in almost all categories. (Abstract shortened by UMI.)...