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

Comparing Slicing Technologies for Digital Light Processing Printing

In additive manufacturing (AM), slicing is a crucial step in process planning to convert a computer-aided design (CAD) model to a machine-specific format. Digital light processing (DLP) printing is an important AM process that has a good surface finish, high accuracy, and fabrication speed and is widely applied in many dental and engineering industries. However, as DLP uses images for fabrication different from other toolpath-based processes, its process planning is understudied. Therefore, the main goal of this paper is to study and compare the slicing technologies for DLP printing. Three slicing technologies are compared: contour, voxelization, and ray-tracing

Development of an Automated Multiple Material Stereolithography Machine

An automated Multiple Material Stereolithography (MMSL) machine was developed by integrating components of a 3D Systems 250/50 stereolithography (SL) machine in a separate stand-alone system and adapting them to function with additional components required for MMSL operation. We previously reported retrofitting a 250/50 SL machine with multiple vats to accommodate multiple material fabrication for building a wide variety of multi-material models (Wicker et al., 2004). In the MMSL retrofit, spatial constraints limited the multiple vats located circumferentially on a vertical rotating vat carousel to cross-sectional areas of approximately 4.5-inches by 4.5-inches. The limited build size of the retrofitted 250/50 motivated the full development of a new system with multiple material build capabilities comparable to the build envelope of the original 250/50 machine. The new MMSL machine required fabrication of a large system frame, incorporating various 250/50 components and software, and adding a variety of new components and software. By using many existing components and software, the previous engineering development of 3D Systems could be directly applied to this new technology. Components that were transferred from an existing 250/50 to the MMSL machine included the complete optical system (including the optics plate with laser, mirrors, beam expander, scanning mirrors, and focusing lens), the rim assembly (including the laser beam profilers), the associated controllers (computer system, scanning mirror controller, power supply-vat controller) and the wiring harness. In addition to the new frame, the MMSL machine required the development of a new rotating vat carousel system, platform assembly, multi-pump filling/leveling system, and a custom LabVIEW® control system to provide automated control over the MMSL process. The overall operation of the MMSL system was managed using the LabVIEW® program, which also included controlling a new vat leveling system and new linear and rotational stages, while the 3D Systems software (Buildstation 4.0) was retained for controlling the laser scanning process. As a demonstration of MMSL technology, simple multi material parts were fabricated with vertically and horizontally oriented interfaces. The fully functional MMSL system offers enormous potential for fabricating a wide variety of multiple material functional devices.Mechanical Engineerin

Digitally interpreting traditional folk crafts

The cultural heritage preservation requires that objects persist throughout time to continue to communicate an intended meaning. The necessity of computer-based preservation and interpretation of traditional folk crafts is validated by the decreasing number of masters, fading technologies, and crafts losing economic ground. We present a long-term applied research project on the development of a mathematical basis, software tools, and technology for application of desktop or personal fabrication using compact, cheap, and environmentally friendly fabrication devices, including '3D printers', in traditional crafts. We illustrate the properties of this new modeling and fabrication system using several case studies involving the digital capture of traditional objects and craft patterns, which we also reuse in modern designs. The test application areas for the development are traditional crafts from different cultural backgrounds, namely Japanese lacquer ware and Norwegian carvings. Our project includes modeling existing artifacts, Web presentations of the models, automation of the models fabrication, and the experimental manufacturing of new designs and forms

INVESTIGATING PRESENT AND FUTURE INTERACTIONS BETWEEN RADIO FREQUENCY IDENTIFICATION, ADDITIVE MANUFACTURING AND SUPPLY CHAIN MANAGEMENT

A screening experiment was paired with research observing the past, present and futures of additive manufacturing (a.k.a. rapid prototyping, 3D printing), radio frequency identification, and supply chain management. The experiment tested different properties of objects created with a desktop fused deposition modelling printer to observe if any single factors or interactions affected the read range of embedded passive UHF RFID inlay. The combination of material and infill percentage had a statistically significant effect on read range, however the analysis is weak since the data could not justify the normality assumption of ANOVA. Furthermore, the size of the effect was small enough to deny any practical difference. From the experiment and research, several presently capable interactions between AM and RFID were commented on. Future interactions between AM, RFID and SCM were also discussed, and a common relationship to physical objects was drawn

Optimization and visualization of rapid prototyping process parameters.

The optimal selection of rapid prototyping (RP) process parameters is a great concern to RP designers. When dealing with this problem, different build objectives have to be taken into consideration. Using virtual rapid prototyping (VRP) systems as a visualization tool to verify the optimally selected process parameters will assist designers in taking critical decisions regarding modeling of prototypes. This will lead to substantial improvements in part accuracy using minimal number of iterations, and no physical fabrication until confident enough to do so. The purpose of this thesis is to demonstrate that virtual validation of optimally selected process parameters can significantly reduce time and effort spent on traditional RP experimentation. To achieve the goal of this thesis, a multi-objective optimization technique is proposed and a model is generated taking into consideration different build objectives, which are surface roughness, support structure volume, build time and dimensional accuracy. The multi-objective method used is the weighted sum method, where a single utility function has been formulated, which combines all the objective functions together. The orders of magnitudes have been normalized, and finally weights have been assigned for each objective function in order to create the general formulation. (Abstract shortened by UMI.)Dept. of Industrial and Manufacturing Systems Engineering. Paper copy at Leddy Library: Theses & Major Papers - Basement, West Bldg. / Call Number: Thesis2004 .E47. Source: Masters Abstracts International, Volume: 43-03, page: 0959. Adviser: Waguih ElMaraghy. Thesis (M.A.Sc.)--University of Windsor (Canada), 2004