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

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

Layered Fabrication of Branched Networks Using Lindenmayer Systems

A current challenge impeding the growth of bone tissue engineering is the lack of functional scaffolds of geometric sizes greater than 10mm due to the inability of cells to survive deep within the scaffold. It is hypothesized that these scaffolds must have an inbuilt nutrient distribution network to sustain the uniform growth of cells. In this paper, we seek to enhance the design and layered fabrication of scaffold internal architecture through the development of Lindenmayer systems, a graphical language based theory to create nutrient delivery networks. The scaffolds are fabricated using the Texas Instruments DLP™ system through UV‐photopolymerization to produce polyethylene glycol hydrogels with internal branch structures. The paper will discuss the Lindenmayer system, process planning algorithms, layered fabrication of samples, challenges and future tasks.Mechanical Engineerin

Computer Aspects of Solid Freeform Fabrication: Geometry, Process Control, and Design

Solid Freefonn Fabrication (SFF) is a class of manufacturing technologies aimed at the production of mechanical components without part-specific tooling or process planning. Originally used for creating modelsfor visualization, many industrial users of SFF technologies are realizing the greater potentialofSFF as legitimate manufacturing processes for producing patterns and, in some cases, functional.parts. Thus, SFF is becoming an important aspect of the product realization process in these industries. Solid Freefonn Fabrication arose from the dream of "push-button" prototyping, in which solid reproductions of three-dimensional geometric models are created automatically under computer control. Perhaps more than any other class of manufacturing technologies, computer software development has been an integral part of the emergence of SFF. As SFF technologies evolve toward the ability to create functional parts, computer issues gain more importance. This paper discusses three aspects of software design for SFF: processing of geometric data, global and local control of SFF processes, and computer-based analysis and design for SFF manufacturing. The discussion of geometric processing issues focuses on accuracy and completeness of input models, and the algorithms required to process such models. The interplay between the physics of SFF processing and the desired output geometry is discussed in terms of the development of model-based control algorithms for SFF. These two areas, geometric processing and control, are necessary for the practical implementation of any SFF technology. However, for SFF to realize its potential as an alternative for manufacturing functional parts, engineers must be provided with analysis and design tools for predicting mechanical properties, ensuring dimensional accuracy, choosing appropriate materials, selecting process parameter values, etc. For each of these three different but related areas of software design, the state-of-theart is assessed, contemporary research is summarized, and future needs are outlined.Mechanical Engineerin

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

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

Biomimetic Design and Fabrication of Interior Architecture of Tissue Scaffolds Using Solid Freeform Fabrication

Modeling, design and fabrication of tissue scaffolds with intricate architecture, porosity and pore size for desired tissue properties presents a challenge in tissue engineering. This paper will present the details of our development in designing and fabrication of the interior architecture of scaffolds using a novel design approach. The Interior Architecture Design (IAD) approach seeks to generate scaffold layered freeform fabrication tool path without forming complicated 3D CAD scaffold models. This involves: applying the principle of layered manufacturing to determine the scaffold individual layered process planes and layered contour; defining the 2D characteristic patterns of the scaffold building blocks (unit cells) to form the Interior Scaffold Pattern; and the generation of process tool path for freeform fabrication of these scaffolds with the specified interior architecture. Feasibility studies applying the IAD algorithm to example models and the generation of fabrication planning instructions will be presented.Mechanical Engineerin

Octree-based production of near net shape components

Near net shape (NNS) manufacturing refers to the production of products that require a finishing operation of some kind. NNS manufacturing is important because it enables a significant reduction in: machining work, raw material usage, production time, and energy consumption. This paper presents an integrated system for the production of near net shape components based on the Octree decomposition of 3-D models. The Octree representation is used to automatically decompose and approximate the 3-D models, and to generate the robot instructions required to create assemblies of blocks secured by adhesive. Not only is the system capable of producing shapes of variable precision and complexity (including overhanging or reentrant shapes) from a variety of materials, but it also requires no production tooling (e.g., molds, dies, jigs, or fixtures). This paper details how a number of well-known Octree algorithms for subdivision, neighbor findings, and tree traversal have been modified to support this novel application. This paper ends by reporting the construction of two mechanical components in the prototype cell, and discussing the overall feasibility of the system

Virtual assembly rapid prototyping of near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel non-layered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper

Systems Issues in Solid Freeform Fabrication

This paper is concerned with the systems aspects of the Solid Freeform Fabrication (SFF) technology, i.e., the issues that deal with getting an external geometric CAD model to automatically control the physical layering fabrication process as directly as possible, regardless ofthe source of the model. The general systems issues are described, the state of systems research is given, and open research questions are posed.Mechanical Engineerin