Incorporate sensors into gears with 3D printing ...

Integrating sensors into rotational mechanisms could make it possible for engineers to build smart hinges that know when a door has been opened, or gears inside a motor that tell a mechanic how fast they are rotating. MIT engineers have now developed a way to easily integrate sensors into these types of mechanisms, with 3D printing.

Even though advances in 3D printing enable rapid fabrication of rotational mechanisms, integrating sensors into the designs is still notoriously difficult. Due to the complexity of the rotating parts, sensors are typically embedded manually, after the device has already been produced.

However, manually integrating sensors is no easy task. Embed them inside a device and wires might get tangled in the rotating parts or obstruct their rotations, but mounting external sensors would increase the size of a mechanism and potentially limit its motion.

Instead, the new system the MIT researchers developed enables a maker to 3D print sensors directly into a mechanism's moving parts using conductive 3D printing filament. This gives devices the ability to sense their angular position, rotation speed, and direction of rotation.

With their system, called MechSense, a maker can manufacture rotational mechanisms with integrated sensors in just one pass using a multi-material 3D printer. These types of printers utilize multiple materials at the same time to fabricate a device.

To streamline the fabrication process, the researchers built a plugin for the computer-aided design software SolidWorks that automatically integrates sensors into a model of the mechanism, which could then be sent directly to the 3D printer for fabrication.

MechSense could enable engineers to rapidly prototype devices with rotating parts, like turbines or motors, while incorporating sensing directly into the designs. It could be especially useful in creating tangible user interfaces for augmented reality environments, where sensing is critical for tracking a user's movements and interaction with objects

"A lot of the research that we do in our lab involves taking fabrication methods that factories or specialized institutions create and then making then accessible for people. 3D printing is a tool that a lot of people can afford to have in their homes. So how can we provide the average maker with the tools necessary to develop these types of interactive mechanisms? At the end of the day, this research all revolves around that goal," says Marwa AlAlawi, a mechanical engineering graduate student and lead author of a paper on MechSense.

…. find more information at MIT.EDU