2,894 research outputs found
From 3D Models to 3D Prints: an Overview of the Processing Pipeline
Due to the wide diffusion of 3D printing technologies, geometric algorithms
for Additive Manufacturing are being invented at an impressive speed. Each
single step, in particular along the Process Planning pipeline, can now count
on dozens of methods that prepare the 3D model for fabrication, while analysing
and optimizing geometry and machine instructions for various objectives. This
report provides a classification of this huge state of the art, and elicits the
relation between each single algorithm and a list of desirable objectives
during Process Planning. The objectives themselves are listed and discussed,
along with possible needs for tradeoffs. Additive Manufacturing technologies
are broadly categorized to explicitly relate classes of devices and supported
features. Finally, this report offers an analysis of the state of the art while
discussing open and challenging problems from both an academic and an
industrial perspective.Comment: European Union (EU); Horizon 2020; H2020-FoF-2015; RIA - Research and
Innovation action; Grant agreement N. 68044
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Converting a CAD Model into a Manufacturing Model for the Components Made of a Multiphase Perfect Material
To manufacture the component made of a multiphase perfect material (including homogeneous
and multi heterogeneous materials), it CAD model should be processed and converted into
layered manufacturing model for further transformation of numerical control (NC) coding. This
paper develops its detailed approaches and corresponding software. The process planning is made
first and includes: (1) determining the build orientation of the component; and (2) slicing the
component into layers adaptively according to different material regions since different materials
have different optimal layer thickness for manufacturing. After the process planning, the layered
manufacturing models with necessary information, including fabrication sequence and material
information of each layer, are fully generated.Mechanical Engineerin
Research Towards High Speed Freeforming
Additive manufacturing (AM) methods are currently utilised for the manufacture of prototypes and low volume, high cost parts. This is because in most cases the high material costs and low volumetric deposition rates of AM parts result in higher per part cost than traditional manufacturing methods. This paper brings together recent research aimed at improving the economics of AM, in particular Extrusion Freeforming (EF).
A new class of machine is described called High Speed Additive Manufacturing (HSAM) in which software, hardware and materials advances are aggregated. HSAM could be cost competitive with injection moulding for medium sized medium quantity parts. A general outline for a HSAM machine and supply chain is provided along with future required research
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Process Planning Based on User Preferences
Typical approaches to adaptive slicing in previous literature have typically used surface finish
requirements to control the slicing process. As a result, slice schemes improve the part's surface
quality, but do not enable explicit trade-offs between finish and build time. The purpose of this
article is to present a process planning method that enables the preferences of the user for surface
finish, build time, and accuracy to control how trade-offs are made in a process plan. A multiobjective goal formulation is used by this method to evaluate how well user preferences are met by
a process plan. This method consists of three modules, for determining part orientation, for slicing
the part, and for determining other parameter values. An example with several scenarios
representing different user preferences is provided to illustrate the process planning method.Mechanical Engineerin
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Form Accuracy Analysis of Cylindrical Parts Produced by Rapid Prototyping
Solid Freeform fabrication processes are being considered for creating fit and assembly
nature functional parts. It is extremely important that these parts are within allowable
dimensional and geometric tolerance. The part accuracy produced by rapid prototyping process
is greatly affected by the relative orientation of build and face normal directions. A systematic
method is needed to find the reliability of the created product. This paper discusses the work
done in this area and the effect of build orientation on the part form accuracy analysis of each
specified tolerance like circularity and cylindricity. Feasible build direction that can be used to
satisfy those tolerances is identified. It will help process engineer in selecting a build direction
that can satisfy a mathematical model of form tolerance.Mechanical Engineerin
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Rotational 3D Printing of Sensor Devices using Reactive Ink Chemistries
This paper charts progress in three key areas of a project supported by both UK
government and UK industry to manufacture novel sensor devices using rotary 3D printing
technology and innovative ink chemistries; (1) the development of an STL file slicing algorithm
that returns constant Z height 2D contour data at a resolution that matches the given print head
setup, allowing digital images to be generated of the correct size without the need for scaling;
(2) the development of image transformation algorithms which allow images to be printed at
higher resolutions using tilted print heads and; (3) the formulation of multi part reaction inks
which combine and react on the substrate to form solid material layers with a finite thickness. A
Direct Light Projection (DLP) technique demonstrated the robustness of the slice data by
constructing fine detailed three dimensional test pieces which were comparable to identical parts
built in an identical way from slice data obtained using commercial software. Material systems
currently under investigation include plaster, stiff polyamides and epoxy polymers and
conductive metallic’s. Early experimental results show conductivities of silver approaching
1.42x105 Siemens/m.Mechanical Engineerin
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A Slicing Procedure for 5-Axis layered Manufacturing
The 5-axis layered manufacturing technology facilitates fabrication of a part with
overhanging features without the use of supports, thereby making a direct-to-use part from the
layered manufacturing technology a reality. In this paper we describe a direct slicing procedure
for a CAD model, a crucial process planning task for the 5-axis layered manufacturing. The
neutral exchange format IGES is used as the slice format. The G and M codes for a CNC 5-axis
laser deposition machine are generated from the slice format and the deposition process is
simulated. Implemented examples are included to explain the slicing procedure. Exciting
possibilities for the future work on the slicing procedure are discussed.Mechanical Engineerin
Multi-Axis Planning System (MAPS) for Hybrid Laser Metal Deposition Processes
This paper summarizes the research and development of a Multi-Axis Planning System (MAPS) for hybrid laser metal deposition processes. The project goal is to enable the current direct metal deposition systems to fully control and utilize multi-axis capability to make complex parts. MAPS allows fully automated process planning for multi-axis layered manufacturing to control direct metal deposition machines for automated fabrication. Such a capability will lead to dramatic reductions in lead time and manufacturing costs for high-value, low-volume components with high performance material. The overall approach, slicing algorithm, machine simulation for planning validation, and the planning results will be presented
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Orthopedic Surgery Planning Based on the Integration of Reverse Engineering and Rapid Prototyping
This paper describes orthopedic surgical planning based on the integration of RE and RP.
Using symmetrical characteristics of the human body, CAD data of the original bone without
damages for the injured extent are generated from a mirror transformation of undamaged bone
data for the uninjured extent. The physical model before the injury is manufactured from RP
apparatus. Surgical planning, such as the selection of the proper implant, pre-forming of the
implant, decision of fixation positions and incision sizes, etc., is determined by a physical
simulation using the physical model. In order to examine the applicability and efficiency of
surgical planning technology for orthopedics, various case studies, such as a proximal tibia
plateau fracture, a distal tibia comminuted fracture and an iliac wing fracture of pelvis, are
carried out. As a result of the examination, it has been shown that the orthopedic surgical
planning based on the integration of RE and RP is an efficient surgical tool.Mechanical Engineerin
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Direct Slicing of STEP Based NURBS Models for Solid Freeform Fabrication
Direct slicing of CAD models to generate process planning instructions for solid freeform
fabrication may overcome inherent disadvantages of using STL format in terms of the process
accuracy, ease of file management, and incorporation of multiple materials. This paper will
present the results of our development of a direct slicing algorithm for layered freeform
fabrication. The direct slicing algorithm was based on a neutral, international standard (ISO
10303) STEP-formatted NURBS geometric representation and is intended to be independent of
any commercial CAD software. The following aspects of the development effort will be
presented: 1) Determination of optimal build direction based upon STEP-based NURBS models;
2) Adaptive subdivision of NURBS data for geometric refinement; and 3) Ray-casting slice
generation into sets of raster patterns. Feasibility studies applying the direct slicing algorithm to
example models and the generation of fabrication planning instructions involving multi-material
structures will also be presented.Mechanical Engineerin
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