Solid Freeform Fabrication for Autonomous Manufacturing of Complete Mobile Robots

Solid freeform fabrication (SFF) allows 3D-printing of arbitrarily shaped structures, directly from computer-aided design (CAD) data. SFF has traditionally focused on printing passive mechanical parts. Advances in this technology and developments in materials science make it feasible to begin the development of a single, compact, robotic SFF system – including a small set of materials which can produce complete, active, functional electromechanical devices mobile robots, for instance. We are advancing steadily toward a complete “library of freeform functionalities,” and successes thus far have included the freeform fabrication of zinc-air batteries, conductive wiring, flexure joints, and combinations of these with thermoplastic structures. Several essential functionalities – actuation, sensing, and control electronics still remain to be realized before complete electromechanical systems can be produced via SFF. Conducting polymers (CP) are a class of materials which can be used to produce all of these. Meanwhile, research into electromechanically active materials has produced other candidate materials for freeform fabricated actuators. We have succeeded in manually producing air-operable actuators that have processing and operating requirements that are compatible with our power source and mechanical component library elements. Such a functionally complete, compact fabrication technology, deployed as part of a machine ecosystem or human/robotic exploration mission, offers an essential capability for repair and extension of other machines, recycling of high-value materials, and fabrication completely new tools, machines or robots.