Structural electronics has garnered significant attention in the past decade. However, there remains a lack of a systematic approach in designing and manufacturing sensors that leverage both mechanical and electronic properties of materials for different applications. In this paper, we introduce a method for designing piezoresistive force sensors utilizing structural electronics and 3D printing techniques. Based on the principles of piezoresistive force sensing, we defined the geometric profile of the sensor by simultaneously maximizing strain and ensuring as uniform as possible stress distribution across the geometry. CAD models of the sensors were then formulated based on the optimized profile and fabricated using conductive filaments and the material extrusion 3D printing technique. Subsequently, we evaluated the accuracy, the sensitivity, and part-to-part variations of the sensors during loading and unloading. The influence of environmental temperature and humidity on the sensor's response were also investigated and compensated. Experiment results demonstrated the feasibility of the proposed method and revealed potential application domains, as well as limitations of the sensors.

4D-scans of dynamic deformable human body parts help researchers have a better understanding of spatiotemporal features. However, reconstructing 4D-scans utilizing multiple asynchronous cameras encounters two main challenges: 1) finding dynamic correspondences among different frames captured by each camera at the timestamps of the camera in terms of dynamic feature recognition, and 2) reconstructing 3D-shapes from the combined point clouds captured by different cameras at asynchronous timestamps in terms of multi-view fusion. Here, we introduce a generic framework able to 1) find and align dynamic features in the 3D-scans captured by each camera using the nonrigid-iterative-closest-farthestpoints algorithm; 2) synchronize scans captured by asynchronous cameras through a novel ADGC-LSTMbased-network capable of aligning 3D-scans captured by different cameras to the timeline of a specific camera; and 3) register a high-quality template to synchronized scans at each timestamp to form a highquality 3D-mesh model using a non-rigid registration method. With a newly developed 4D-foot-scanner, we validate the framework and create the first open-access data-set, namely the 4D-feet. It includes 4Dshapes (15 fps) of the right and left feet of 58 participants (116 feet including 5147 3D-frames), covering significant phases of the gait cycle. The results demonstrate the effectiveness of the proposed framework, especially in synchronizing asynchronous 4D-scans.

The geometric shapes and the relative position of coils influence the performance of a three-dimensional (3D) inductive power transfer system. In this paper, we propose a coil design method for specifying the positions and the 3D shapes of a pair of coils to transmit the desired power. Given region of interests (ROIs) for designing the transmitter and the receiver coils on two surfaces, the transmitter coil is generated around the center of its ROI. The center of the receiver coil is estimated as a random seed position in the corresponding 3D surface. At this position, we use the heatmap method with electromagnetic constraints to iteratively extend the coil until the desired power can be transferred via the set of coils. In each step, the shape of the extension, i.e., a new turn of the receiver coil, is found as a spiral curve based on the convex hulls of the 2D projected adjacent turns along their normal direction. Then, the optimal position of the receiver coil is found by maximizing the efficiency of the system. In the next step, the position and the shape of the transmitter coil are optimized based on the fixed receiver coil using the same method. This optimization process iterates until an optimum is reached. Simulations and experiments with digitally fabricated prototypes were conducted and the effectiveness of the proposed 3D coil design method was verified.

The geometric shapes of coils influence the performance of a 3D IPT system. In this paper, we proposed a 3D coil design method based on (3D) printing electronics. Given a 3D transmitter coil, the center position of the receiver coil is estimated as a random seed position in the corresponding 3D surface first. At this position, we use the heatmap method with electromagnetic constraints to iteratively extend the coil until the desired power can be transferred via the coil. For each extension of the coil, i.e. a new turn, the shape of the coil is optimized by calculating the convex hull of the new turn in the 2D projection plane. Using this method, we are able to generate a receiver coil to transmit “just enough” power at a given seed position. Then, by fixing the receiver coil, the 3D shape of the transmitter coil can be optimized as well. This zig-zag optimization process iterates until there are few changes of the position and 3D shapes in the iteration. Experiment results with Ansys Maxwell verified the effectiveness of the proposed 3D coil design method, and highlighted possible future research directions as well.

Acquiring an accurate 3D scan of the human hand is a challenging task, mainly due to the complicated geometry and the instability of the hand. In this paper, we present a low-cost photogrammetry-based scanner that is designed for scanning the human hand. The scanner has fifty modules, each has a Raspberry Pi with an 8-megapixels camera. They are uniformly positioned in two parallel frames and 96% of a hand surface can be viewed by at least 3 cameras. Using the timestamp method, we synchronize the shutters of the 50 cameras within the range of 80 ms to minimize the influence of the instability of the hand. Moreover, the scanner is easy to build with its modular design, and easy to operate with a laptop that is connected to the system by WiFi. Using a 3D printed prosthetic hand, we compared the 3D scanning accuracy of the proposed scanner with the Artec Spider® scanner. The mean absolute error between the two scans is 0.62 ± 0.28 mm. It is concluded that the proposed hand scanner can be used as a low-cost yet accurate tool in many applications, such as personalized product design.

2D coil design limits the use of wireless power transfer (WPT) in many products with freeform outer shapes. In this paper, enabled by 3D printed electronics, we propose a systematic approach to design and fabricate 3D coils for WPT. Based on the circular spiral and rectangular spiral patterns, 3D receiver and transmitter coils can be generated on an arbitrarily selected region of a product and its offset, respectively. Mathematical models are proposed to estimate the self-inductance and the mutual-inductance of the 3D arbitrarily shaped coils for 3D WPT. This leads to a new design approach of a 3D WPT system. Several sets of 3D printed WPT systems were designed, simulated, and prototyped to demonstrate the effectiveness of the proposed design approach as well as the mathematical models. The calculation speed of the proposed mathematical models is 30 times faster than the simulation, and compared with the measurement results, the calculation results have mean absolute errors of 2.63% and 4.45% regarding the self- and the mutual-inductance, where the simulation results have mean absolute errors of 1.20% and 2.38%, respectively. Measurements also indicate that with a 5V input, the prototypes are able to deliver 1-watt power at an efficiency ranging between 20.9% and 25.3%. It was concluded that the proposed approach is feasible and promising for designing and manufacturing WPT using 3D printed electronics.