Compliant Mechanism Moulding via NiChrome Wire Sintering Method

This research proposed a unique process for the rapid manufacturing of large-scale compliant mechanism components. Using the characteristics of the NiChrome wire sintering method, it aims to rapidly fabricate a large-scale compliant mechanism model at low cost. NiChrome wire sintering is a method in which NiChrome wire is wound into a target pattern and then placed in a hot-melt material (TPU powder) to be energized and moulded. The low cost, high degree offreedom and one-piece characteristic of this new method bring new possibilities for the manufacturing process of compliant mechanism components. This research applies a new fabrication method to reduce the production cost and manufacturing difficulty of large kinetic installations. In benefitting from the non-mechanical wear characteristics of compliant mechanisms, the service life of manufactured installations can be greatly prolonged as well. The new fabrication method demonstrates an efficient way to produce a large scale of kinetic structure and provides a toolkit for designers.