Researchers at the University of Pittsburgh are using lights of multiple wavelengths and neural networks to improve the finishing process of photopolymer additive manufacturing (PAM). Xiayun Zhao, an assistant professor of mechanical engineering and materials science at the institute, has received a $657,610 Faculty Early Career Development award from the National Science Foundation for her research. Read on to learn more.
Curb Overcuring
Zhao’s research aims to develop a smart, novel digital light processing (DLP) method that capitalizes on photoinhibition induced by a second wavelength light to curb curing parts. This process has been named DLP2Curb.
DLP2Curb
There are three main phases to the research. In the first, Zhao’s team will try to understand how the DLP2Curb process works and how different materials behave under these conditions. This work will involve creating a Digital Twin, a complex computer model that will simulate how tweaks made to the process or material will change the outcome.
In the second part, the team will use tools like interferometric and ultrasonic monitoring systems to watch the materials in real-time.
In the third and final part, Zhao will develop a way to control the process in real time, using deep reinforcement learning of model predictions and in-situ measurements to guide the printing process.
“Using a single wavelength to cure polymers while printing is already complex. Adding a second escalates that complexity, but we can use machine learning to enhance our accuracy and accelerate our progress,” said Zhao.
“Conventional machine learning calculations take time and aren’t fast enough for real-time control yet, but the digital twin we’ll develop as part of this project based on the state-of-the-art physics-informed neural networks will help us in that endeavor.”
Outreach
Zhao’s CAREER award will also offer educational opportunities to prepare and encourage the next generation of leaders to pursue manufacturing-related careers and promote diversity in the STEM field. One of her outreach initiatives will be a collaboration with the Carnegie Science Center to organize summer camps that will introduce AI and metrology-assisted additive manufacturing to students and provide them with practical 3D printing experience in the manufacturing sector.
If successful, this research will have a significant impact on various applications, including biochips, electrodes, soft robots, and metamaterials.
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