arXiv subjects

Moran Bercovici

Publications and source records attributed to Moran Bercovici.

At least 19 recordsLinked to original sources

arXiv2026

Shaping liquids into space structures - microgravity-assisted design and manufacturing of minimal surfaces

This work advances a fundamentally new approach to space-based construction by using liquid self organization in microgravity as a generative design and fabrication principle. Building on the LiquiFab method, we demonstrate how minimal surface architectures - traditionally dependent on complex additive manufacturing - can instead emerge directly from the physics of fluid interfaces shaped by programmable boundary conditions. We present a simulation-to-fabrication workflow, that includes a boundary-driven minimal-surface solver integrated in Grasshopper/Rhino, and an experimental system that implements in a neutral buoyancy environment simulating microgravity. This enables the generation of customizable Schwarz-P-inspired with tunable geometry and thickness, illustrating a scalable pathway for material-efficient, on-orbit fabrication. To validate performance in true microgravity, a flight experiment on the International Space Station is scheduled for the first quarter of 2027 and we here detail the additional considerations required for this experiment.

physics.app-ph↗

arXiv2026

Zero-waste manufacturing of ophthalmic lenses by direct Fluidic Shaping in arbitrary domains

The conventional manufacturing of ophthalmic lenses is an inefficient subtractive process where up to 97% of the material is discarded through grinding, polishing, and edging. Fluidic Shaping has emerged as a powerful alternative, utilizing surface tension to form optical-quality surfaces. While the approach enabled the creation of ophthalmic lenses without grinding or polishing, it was limited to lenses with a circular or elliptical footprint and still required the wasteful edging process to fit the lenses into the eyewear rims. Here, the Cookie Cutter algorithm is introduced, generalizing the Fluidic Shaping approach to be applicable to arbitrary domains, thus eliminating all subtractive processes. This mathematical framework calculates the unique varying edge-height required for a boundary frame, allowing a liquid polymer to naturally settle into a target spherocylindrical prescription within an arbitrary rim footprint. By utilizing neutral buoyancy to negate gravity, the liquid polymer is shaped solely by surface tension and subsequently cured, resulting in a lens that fits directly into commercial eyewear rims without any mechanical post-processing. The method is validated experimentally, demonstrating the fabrication of lenses compatible with standard eyewear rims. This approach represents a complete additive manufacturing solution, enabling end-to-end zero-waste production of prescription eyeglasses.

physics.app-ph↗

arXiv2026

Fluidic Shaping over arbitrary domains: theory and high order finite-elements solver

Fluidic Shaping is a novel method for fabrication of optical components based on the equilibrium state of liquid volumes in neutral buoyancy, subjected to geometrical constraints. The underlying physics of this method is described by a highly nonlinear partial differential equation with Dirichlet boundary conditions and an integral constraint. To date, useful solutions for such optical liquid surfaces could be obtained analytically only for the linearized equations and only on circular or elliptical domains. A numerical solution for the non-linear equation was suggested, but only for the axi-symmetric case. Such solutions are, however, insufficient as they do not capture the full range of optical surfaces. Arbitrary domains offer an important degree of freedom for creating complex optical surfaces, and the nonlinear terms are essential for high quality solutions. Moreover, in the context of optics, it is not sufficient to resolve the shape of the surface, and it is essential to obtain accurate solutions for its curvature, which governs its optical properties. We here present the theoretical foundation for the Fluidic Shaping method over arbitrary domains, and the development of a high order (quintic) finite element numerical solver, capable of accurately resolving the topography and curvature of liquid interfaces on arbitrary domains. The code is based on reduced quintic finite elements, which we have modified to capture curved boundaries. We compare the results against low order finite elements and non-deformed high order elements, demonstrating the importance of high order approximations of both the solution and the domain. We also show the usability of the code for the prediction of optical surfaces derived from complex boundary conditions.

physics.flu-dyn↗

arXiv2026

Modeling the Thermal Behavior of Photopolymers for In-Space Fabrication

Future long-duration space missions will require in-situ, on-demand manufacturing of tools and components. Photopolymer-based processes are attractive for this purpose due to their low energy requirements, volume efficiency, and precise control of curing. However, photopolymerization generates significant heat, which is difficult to regulate in microgravity where natural convection is absent, leading to defects such as surface blistering and deformation. In this work, we combine experimental studies and modeling to address these thermal challenges. We report results from International Space Station (ISS) experiments and a dedicated parabolic flight campaign, which confirm that suppressed convective heat transfer in microgravity exacerbates thermal buildup and defect formation. Building on these observations, we present a predictive thermal model that couples heat transfer, light absorption, and evolving material properties to simulate polymerization and temperature evolution under terrestrial and microgravity conditions. Laboratory validation demonstrates strong agreement between model predictions and measured temperature profiles. Applying the model to the ISS experiments, we show that the model accurately reproduces experimentally observed blistering in TJ-3704A, a commercial acrylate-based polymer resin, while also predicting defect-free outcomes for Norland optical adhesives. The model functions as a design tool for defect-free in-space manufacturing, enabling selection of polymer properties, exposure strategies, and environmental conditions that together inhibit excess thermal buildup, paving the way for scalable, reliable in-situ manufacturing during future missions.

cond-mat.mtrl-sci↗

arXiv2025

LiquiFab -- Building with liquids in weightlessness

Existing digital manufacturing methods can be broadly divided into subtractive approaches, where material is removed from a bulk to reveal the desired form, and additive methods, in which material is introduced voxel-by-voxel to create an object. We here show a fundamentally different method for the fabrication of three-dimensional objects that is neither subtractive nor additive. Instead of removal or layer-by-layer material deposition, in LiquiFab we shape an entire volume of liquid polymer by subjecting it to a set of geometrical constraints under conditions of weightlessness. The physics of liquid interfaces then drives the polymer to naturally adopt a configuration that minimizes its surface energy. On Earth, we achieve weightlessness through neutral buoyancy, and show that a small, well-defined set of boundary surfaces can be used to drive the liquid into a desired form that is then solidified. By sequentially applying this process, complex architectures can be assembled from successive liquid-formed elements. Unlike additive manufacturing, where every point within the object must be individually visited by a print head or light field, LiquiFab forms the entire structure simultaneously. This makes the process highly scalable and opens the door to rapid manufacturing of large objects both on Earth and in space.

cond-mat.soft↗

arXiv2025

In-space manufacturing of optical lenses: Fluidic Shaping aboard the International Space Station

In-space manufacturing technologies are vital for enabling advanced space missions and addressing logistical limitations of space exploration. While additive manufacturing has progressed rapidly, it still falls short of delivering the ultra-smooth surfaces required for optical elements. Fluidic Shaping is a novel method that harnesses surface tension under microgravity to form optical components with exceptionally smooth surfaces. This study demonstrates the feasibility and potential of Fluidic Shaping as a method for manufacturing optical components in space through two experiments performed aboard the International Space Station (ISS) during the Ax-1 mission. The first experiment involved fabricating centimeter-scale polymer lenses, solidifying them via ultraviolet (UV) curing, and analyzing the resultant optics upon their return to Earth. While sub-nanometric surface smoothness was achieved, some polymer lenses displayed unexpected thermo-chemical deformations, indicating complex polymerization dynamics unique to the microgravity environment. In the second experiment, a large-scale, 172 mm diameter water lens was deployed, confirming Fluidic Shaping's scalability and demonstrating basic optical functionality through image analysis. These experiments collectively underline the technique's relevance for both small-scale optics and large-aperture applications. Our results highlight critical considerations for future research, including optimizing polymerization processes and refining liquid-handling methods to advance practical, in-space optical manufacturing capabilities.

physics.optics↗

arXiv2025

Fluid dynamics of a liquid mirror space telescope

Large aperture telescopes are pivotal for exploring the universe, yet even with state-of-the-art manufacturing and launch technology, their size is limited to several meters. As we aim to build larger telescopes - extending tens of meters - designs in which the main mirror is based on liquid deployment in space are emerging as promising candidates. However, alongside their enormous potential advantages, liquid-based surfaces present new challenges in material science, mechanics, and fluid dynamics. One of the fundamental questions is whether it is possible for such surfaces to maintain their precise optical shape over long durations, and in particular under the forces induced by the telescope's accelerations. In this paper, we present a model and a closed-form analytical solution for the non-self-adjoint problem of the dynamics of a thin liquid film pinned within a finite circular domain. We use the 50-meter Fluidic Telescope (FLUTE) concept as the case study, and examine the liquid dynamics of the telescope under both slewing actuation and relaxation regimes, elucidating the role of geometrical parameters and liquid properties. The solutions reveal a maneuvering 'budget' wherein the degradation of the mirror surface is directly linked to the choice of maneuvers and their sequence. By simulating ten years of typical operation, we show that, while the maximal deformation might reach several microns, the spatial distribution of the deformation and their propagation rate allows the telescope to maintain its optical functionality for years, with at least a substantial portion of the aperture remaining suitable for astronomical observations. The model provides valuable insights and guidelines into the performance of liquid-film space telescopes, marking a crucial step toward realizing the potential of this innovative concept.

astro-ph.IM↗

arXiv2024

Fluidic Approach to Corrective Eyewear Manufacturing in Low-Resource Settings

Limited access to corrective eyewear remains a significant medical, societal, and economic challenge, even in the 21st century. More than 1 billion people suffer from uncorrected vision impairment, with the vast majority residing in developing countries. Decades of philanthropic efforts failed to supply even a small fraction of the demand, whereas local manufacturing using standard machining technologies remains out of reach due to inadequate resources. We here show that the Fluidic Shaping approach can be utilized to create a new manufacturing modality for high-quality ophthalmic lenses that entirely eliminates the need for machining, and instead uses surface tension to shape liquid polymer volumes into prescription lenses. We present a compact device wherein a liquid photopolymer is injected into an elliptical frame submerged within an immersion liquid of equal density, resulting in two liquid surfaces whose minimum-energy states correspond to two lens surfaces. After several minutes of curing, a complete solid lens is obtained, requiring no post-processing. We provide an analytical model and experimental validation, showing that all spherical and cylindrical corrections can be attained by simply controlling the volume of the polymer and the frame's eccentricity. We demonstrate the fabrication of complete eyeglasses that meet and exceed industry standards, relying solely on a 1 gallon water container integrated with an array of low-power LEDs.

physics.app-ph↗

arXiv2022

Fluidic Shaping and in-situ Measurement of Liquid Lenses in Microgravity

In the absence of gravity, surface tension dominates over the behavior of liquids. While this often poses a challenge in adapting Earth-based technologies to space, it can also provide an opportunity for novel technologies that utilize its advantages. In particular, surface tension drives a liquid body to a constant-mean-curvature shape with extremely smooth surfaces, properties which are highly beneficial for optical components. We here present the design, implementation and analysis of parabolic flight experiments demonstrating the creation and in-situ measurement of optical lenses made entirely by shaping liquids in microgravity. We provide details of the two experimental systems designed to inject the precise amount of liquid within the short microgravity timeframe provided in a parabolic flight, while also measuring the resulting lens characteristics in real-time using both resolution target-imaging and a Shack-Hartmann wavefront sensing. We successfully created more than 20 liquid lenses during the flights. We also present video recordings of the process, from the lenses creation during microgravity and up until their collapse upon return to gravity. To the best of our knowledge, this is the first time that a purely liquid lens has been created in microgravity, which demonstrates the feasibility of creating and utilizing liquid-based optics in space.

physics.optics↗

arXiv2022

Dynamic control of high-voltage actuator arrays by light-pattern projection on photoconductive switches

The ability to control high-voltage actuator arrays relies, to date, on expensive microelectronic processes or on individual wiring of each actuator to a single off-chip high-voltage switch. Here we present an alternative approach that uses on-chip photoconductive switches together with a light projection system to individually address high-voltage actuators. Each actuator is connected to one or more switches that are nominally OFF unless turned ON using direct light illumination. We selected hydrogenated amorphous silicon as our photoconductive material, and we provide complete characterization of its light to dark conductance, breakdown field, and spectral response. The resulting switches are very robust, and we provide full details of their fabrication processes. We demonstrate that the switches can be integrated in different architectures to support both AC and DC-driven actuators and provide engineering guidelines for their functional design. To demonstrate the versatility of our approach, we demonstrate the use of the photoconductive switches in two distinctly different applications control of micrometer-sized gate electrodes for patterning flow fields in a microfluidic chamber, and control of centimeter-sized electrostatic actuators for creating mechanical deformations for haptic displays.

physics.ins-det↗

arXiv2022

Dynamics of fixed-volume pinned film -- dealing with a non-self-adjoint thin film problem

The use of thin liquid films has expanded beyond lubrication and coatings, and into applications in actuators and adaptive optical elements. In contrast to their predecessors, whose dynamics can be typically captured by modelling infinite or periodic films, these applications are characterized by a finite amount of liquid in an impermeable domain. The global mass conservation constraint, together with common boundary conditions (e.g., pinning) create quantitatively and qualitatively different dynamics than those of infinite films. Mathematically, this manifests itself as a non-self-adjoint problem. This work presents a combined theoretical and experimental study for this problem. We provide a time-dependent closed-form analytical solution for the linearized non-self-adjoint system that arises from these boundary conditions. We highlight that, in contrast to self-adjoint problems, here special care should be given to deriving the adjoint problem to reconstruct the solution based on the eigenfunctions properly. We compare these solutions with those obtained for permeable and periodic boundary conditions, representing common models for self-adjoint thin-film problems. We show that while the initial dynamics are nearly identical, the boundary conditions eventually affect the film deformation as well as its response time. To experimentally illustrate the dynamics and to validate the theoretical model, we fabricated an experimental setup that subjects a thin liquid film to a prescribed normal force distribution through dielectrophoresis, and used high-frame-rate digital holography to measure the film deformation in real-time. The experiments agree well with the model and confirm that confined films exhibit different behaviour which could not be predicted by existing models.

physics.flu-dyn↗

arXiv2022

Programmable thermocapillary shaping of thin liquid films

We present a method that leverages projected light patterns as a mechanism for freeform deformations of a thin liquid film via the thermocapillary effect. We developed a closed-form solution for the inverse problem of the thin-film evolution equation, allowing to obtain the projection pattern required in order to achieve a desired topography. We experimentally implement the method using a computer controlled light projector, which illuminates any desired pattern onto the bottom of a fluidic chamber patterned with heat absorbing metal pads. The resulting heat map induces surface tension gradients in the liquid-air interface, giving rise to thermocapillary flow that deforms the liquid surface. If a polymer is used for the liquid film, it can then be photocured to yield a solid device. Based on the inverse problem solutions and using this system, we demonstrate the fabrication of several diffractive optical elements (DOEs), including phase masks for extended depth of field imaging, and for 3D localization microscopy. The entire process, from projection to solidification, is completed in less than five minutes, and yields a sub-nanometric surface quality without any post-processing.

physics.optics↗

arXiv2021

Fluidic Shaping of Freeform Optical Components

Freeform optical components offer significant compactization of multi-lens systems, as well as advanced manipulation of light that is not possible with traditional systems. However, their fabrication relies on machining processes that are complex, time-consuming, and incompatible with rapid prototyping. This work presents the ability to shape liquid volumes and solidify them into desired freeform components, enabling rapid freeform prototyping with high surface quality. The method is based on controlling the minimum energy state of the interface between a curable optical liquid and an immersion liquid, by dictating a geometrical boundary constraint. The boundary shape is modeled as a cylinder whose arbitrary height is expressed as a Fourier series, allowing for an analytical solution of the resulting freeform surface as a sum of Fourier-Bessel functions. Each of these functions represents a different basic mode, whose superposition creates complex topographies. This solution allows deterministic design of freeform surfaces by controlling three key parameters - the volume of the optical liquid, the density of the immersion liquid, and the shape of the bounding frame. The paper describes a complete workflow for rapid prototyping of such components, and demonstrates the fabrication of a 35 mm diameter freeform component with sub-nanometer surface roughness within minutes.

physics.optics↗

arXiv2021

Shaping liquid films by dielectrophoresis

We present a theoretical model and experimental demonstration of thin liquid film deformations due to a dielectric force distribution established by surface electrodes. We model the spatial electric field produced by a pair of parallel electrodes and use it to evaluate the stress on the interface through Maxwell stresses. By coupling this force with the Young-Laplace equation, we obtain the deformation of the interface. To validate our theory, we design an experimental setup which uses microfabricated electrodes to achieve spatial dielectrophoretic actuation of a thin liquid film, while providing measurements of microscale deformations through digital holographic microscopy. We characterize the deformation as a function of the electrode-pair geometry and film thickness, showing very good agreement with the model. Based on the insights from the characterization of the system, we pattern conductive lines of electrode pairs on the surface of a microfluidic chamber and demonstrate the ability to produce complex two-dimensional deformations. The films can remain in liquid form and be dynamically modulated between different configurations or polymerized to create solid structures with high surface quality.

cond-mat.soft↗

arXiv2020

Fluidic Shaping of Optical Components

Current methods for fabricating lenses rely on mechanical processing of the lens or mold, such as grinding, machining, and polishing. The complexity of these fabrication processes and the required specialized equipment prohibit rapid prototyping of optical components. This work presents a simple method, based on free-energy minimization of liquid volumes, which allows to quickly shape curable liquids into a wide range of spherical and aspherical optical components, without the need for any mechanical processing. After the desired shape is obtained, the liquid can be cured to produce a solid object with nanometric surface quality. We provide a theoretical model that accurately predicts the shape of the optical components, and demonstrate rapid fabrication of all types of spherical lenses (convex, concave, meniscus), cylindrical lenses, bifocal lenses, toroidal lenses, doublet lenses and aspheric lenses. The method is inexpensive and can be implemented using a variety of curable liquids with different optical and mechanical properties. In addition, the method is scale-invariant and can be used to produce even very large optical components, without a significant increase in fabrication time. We believe that the ability to easily and rapidly create high-quality optics, without the need for complex and expensive infrastructure, will provide researchers with new affordable tools for fabricating and testing optical designs.

physics.app-ph↗

arXiv2019

Non-uniform electro-osmotic flow drives fluid-structure instability

We demonstrate the existence of a fluid-structure instability arising from the interaction of electro-osmotic flow with an elastic substrate. Considering the case of flow within a soft fluidic chamber, we show that above a certain electric field threshold, negative gauge pressure induced by electro-osmotic flow causes the collapse of its elastic walls. We combine experiments and theoretical analysis to elucidate the underlying mechanism for instability and identify several distinct dynamic regimes. The understanding of this instability is important for the design of electrokinetic systems containing soft elements.

physics.flu-dyn↗

arXiv2019

Electroosmotic flow dipole: experimental observation and flow field patterning

We experimentally demonstrate the phenomenon of electroosmotic dipole flow that occurs around a localized surface charge region under the application of an external electric field in a Hele-Shaw cell. We use localized deposition of polyelectrolytes to create well-controlled surface charge variations, and show that for a disk-shaped spot, the internal pressure distribution that arises, results in uniform flow within the spot and dipole flow around it. We further demonstrate the superposition of surface charge spots to create complex flow patterns, without the use of physical walls.

cond-mat.soft↗

arXiv2019

Dipolar thermocapillary motor and swimmer

We present a theoretical description and an experimental realization of a thermocapillary dipole induced in a Hele-Shaw cell under a steady temperature gradient. We demonstrate experimentally how several dipoles can be superposed in order to create various 2D flow patterns, and how a confined dipole can act as a thermocapillary motor for driving fluids in microfluidic circuits. In addition, we show how the principles behind the thermocapillary dipole can be applied in order to drive thermocapillary swimmers on fluid-liquid interfaces.

physics.flu-dyn↗