Method and apparatus for performing contactless laser fabrication and propulsion of freely moving structures

1. A method of using a laser for forming an actuator comprising a stationary element and a moveable element, the method comprising:

forming the actuator from a two-dimensional sheet stock using the laser by

laser cutting the sheet stock; and

laser folding the cut two-dimensional sheet stock to make the actuator three dimensional; and

releasing the moveable element of the actuator from the sheet stock using the laser so that the moveable element is made moveable relative to the stationary element of the actuator while the actuator is in use,

wherein the laser cutting, laser folding, and releasing the moveable element are solely accomplished by the laser.

2. The method of claim 1 further comprising moving the moveable element with respect to the sheet stock using laser ablation propulsion to assemble the actuator.

3. The method of claim 1 , wherein, upon releasing the moveable element of the actuator from the sheet stock, the moveable element freely falls under its own weight into a position to assemble the actuator.

4. The method of claim 1 wherein the sheet stock comprises one or more of metal, ceramic, crystalline semiconductors, or glass.

5. The method of claim 4 wherein the metal is nickel, stainless steel, bronze, brass, copper, NiTi shape memory alloy or combinations thereof.

6. The method of claim 1 wherein the moveable element of the actuator is a rotor and the stationary element is an axle holder which holds the rotor.

7. The method of claim 6 , wherein forming the rotor and axle holder comprises: releasing the rotor from the sheet stock, so that the rotor freely falls under its own weight into a position into the axle holder to assemble the actuator.

8. The method of claim 1 wherein the two-dimensional sheet stock is positioned between a supply reel and a take-up reel and the method further comprises:

forming and releasing a first actuator from the two-dimensional sheet stock using the laser;

moving the two-dimensional sheet stock from the supply reel to the take-up reel; and

forming and releasing a second actuator from the two-dimensional sheet stock using the laser.

9. The method of claim 1 wherein the forming of the actuator with the laser comprises localized laser heating to generate plastic stresses for bending at least a portion of the sheet stock.

10. A method of forming an actuator comprising a stationary element and a moveable element, the method comprising:

providing:

a first reel configured for dispensing a two-dimensional sheet stock;

a second reel configured for receiving the two-dimensional sheet stock;

a guide element for providing a flat area of the two-dimensional sheet stock between the dispensing and receiving reels; and

a laser configured to direct a laser beam to the two-dimensional sheet stock in the flat area;

laser cutting the two-dimensional sheet stock with the laser beam;

laser folding the cut two-dimensional sheet stock with the laser beam so as to make the actuator three-dimensional; and

releasing the moveable element from the cut two-dimensional sheet stock using the laser beam so that it is made moveable with respect to the stationary element of the actuator while the actuator is in use,

wherein the laser cutting, laser folding, and releasing the moveable element are solely accomplished by the laser.

11. The method of claim 10 , further comprising depositing a material on the moveable element.

12. The method of claim 10 , further comprising operating a 3D printer to deposit a material on the moveable element.

13. The method of claim 10 , further comprising moving the moveable element with respect to the sheet stock using laser ablation propulsion to assemble the actuator.

14. The method of claim 10 , wherein the sheet stock comprises one or more of metal, ceramic, crystalline semiconductors, or glass.

15. The method of claim 14 , wherein the metal is nickel, stainless steel, bronze, brass, copper, NiTi shape memory alloy or combinations thereof.

16. The method of claim 10 , wherein the moveable element of the actuator is a rotor and the stationary element is an axle holder which holds the rotor.

17. Apparatus for forming an actuator comprising a stationary element and a moveable element, the apparatus comprising:

a first reel configured for dispensing a sheet stock;

a second reel configured for receiving the sheet stock;

a guide element for providing a flat area of the sheet stock between the dispensing and receiving reels; and

a laser configured to direct a laser beam to the sheet stock in the flat area and form laser cuts to the sheet stock, laser fold the cut sheet stock so as to make the actuator three-dimensional actuator, and release the moveable element from the sheet stock so that it becomes moveable with respect to the stationary element of the actuator while the actuator is in use, wherein the cuts, folds and release of the moveable element are solely accomplished by the laser.

18. The apparatus of claim 17 , further comprising a 3D printer configured to deposit material on the moveable element.

19. The apparatus of claim 17 , wherein the sheet stock comprises one or more of metal, ceramic, crystalline semiconductors, or glass.

20. The apparatus of claim 19 , wherein the metal is nickel, stainless steel, bronze, brass, copper, NiTi shape memory alloy or combinations thereof.

21. The method of claim 1 , wherein the laser cutting comprises: cutting material between the moveable element and the sheet stock to leave just one or more release beams joining the two, and the releasing comprises: cutting the one or more release beams to physically separate the moveable element from the sheet stock.

22. The method of claim 2 , wherein the laser ablation propulsion uses the same laser used to laser cut and laser fold the sheet stock.

23. The method of claim 2 , wherein the stationary element of the actuator is a stationary axle holder and the moveable element of the actuator is a rotor with the rotor being moveable within the axle holder while the actuator is in use; the method further comprising:

laser folding the cut two-dimensional sheet metal to form the axle holder and to make the actuator three dimensional; and

moving the rotor using laser ablation propulsion into place in the axle holder to assemble the actuator.