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

Geometric Modeling of Cellular Materials for Additive Manufacturing in Biomedical Field: A Review

Advances in additive manufacturing technologies facilitate the fabrication of cellular materials that have tailored functional characteristics. The application of solid freeform fabrication techniques is especially exploited in designing scaffolds for tissue engineering. In this review, firstly, a classification of cellular materials from a geometric point of view is proposed; then, the main approaches on geometric modeling of cellular materials are discussed. Finally, an investigation on porous scaffolds fabricated by additive manufacturing technologies is pointed out. Perspectives in geometric modeling of scaffolds for tissue engineering are also proposed

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

Designing heterogeneous porous tissue scaffolds for additive manufacturing processes

A novel tissue scaffold design technique has been proposed with controllable heterogeneous architecture design suitable for additive manufacturing processes. The proposed layer-based design uses a bi-layer pattern of radial and spiral layers consecutively to generate functionally gradient porosity, which follows the geometry of the scaffold. The proposed approach constructs the medial region from the medial axis of each corresponding layer, which represents the geometric internal feature or the spine. The radial layers of the scaffold are then generated by connecting the boundaries of the medial region and the layer's outer contour. To avoid the twisting of the internal channels, reorientation and relaxation techniques are introduced to establish the point matching of ruling lines. An optimization algorithm is developed to construct sub-regions from these ruling lines. Gradient porosity is changed between the medial region and the layer's outer contour. Iso-porosity regions are determined by dividing the subregions peripherally into pore cells and consecutive iso-porosity curves are generated using the isopoints from those pore cells. The combination of consecutive layers generates the pore cells with desired pore sizes. To ensure the fabrication of the designed scaffolds, the generated contours are optimized for a continuous, interconnected, and smooth deposition path-planning. A continuous zig-zag pattern deposition path crossing through the medial region is used for the initial layer and a biarc fitted isoporosity curve is generated for the consecutive layer with C-1 continuity. The proposed methodologies can generate the structure with gradient (linear or non-linear), variational or constant porosity that can provide localized control of variational porosity along the scaffold architecture. The designed porous structures can be fabricated using additive manufacturing processes

Survey on Additive Manufacturing, Cloud 3D Printing and Services

Cloud Manufacturing (CM) is the concept of using manufacturing resources in a service oriented way over the Internet. Recent developments in Additive Manufacturing (AM) are making it possible to utilise resources ad-hoc as replacement for traditional manufacturing resources in case of spontaneous problems in the established manufacturing processes. In order to be of use in these scenarios the AM resources must adhere to a strict principle of transparency and service composition in adherence to the Cloud Computing (CC) paradigm. With this review we provide an overview over CM, AM and relevant domains as well as present the historical development of scientific research in these fields, starting from 2002. Part of this work is also a meta-review on the domain to further detail its development and structure

Flow-based fabrication: An integrated computational workflow for design and digital additive manufacturing of multifunctional heterogeneously structured objects

Structural hierarchy and material organization in design are traditionally achieved by combining discrete homogeneous parts into functional assemblies where the shape or surface is the determining factor in achieving function. In contrast, biological structures express higher levels of functionality on a finer scale through volumetric cellular constructs that are heterogeneous and complex. Despite recent advancements in additive manufacturing of functionally graded materials, the limitations associated with computational design and digital fabrication of heterogeneous materials and structures frame and limit further progress. Conventional computer-aided design tools typically contain geometric and topologic data of virtual constructs, but lack robust means to integrate material composition properties within virtual models. We present a seamless computational workflow for the design and direct digital fabrication of multi-material and multi-scale structured objects. The workflow encodes for and integrates domain-specific meta-data relating to local, regional and global feature resolution of heterogeneous material organizations. We focus on water-based materials and demonstrate our approach by additively manufacturing diverse constructs associating shape-informing variable flow rates and material properties to mesh-free geometric primitives. The proposed workflow enables virtual-to-physical control of constructs where structural, mechanical and optical gradients are achieved through a seamless design-to-fabrication tool with localized control. An enabling technology combining a robotic arm and a multi-syringe multi nozzle deposition system is presented. Proposed methodology is implemented and full-scale demonstrations are included

Challenges and Status on Design and Computation for Emerging Additive Manufacturing Technologies

The revolution of additive manufacturing (AM) has led to many opportunities in fabricating complex and novel products. The increase of printable materials and the emergence of novel fabrication processes continuously expand the possibility of engineering systems in which product components are no longer limited to be single material, single scale, or single function. In fact, a paradigm shift is taking place in industry from geometry-centered usage to supporting functional demands. Consequently, engineers are expected to resolve a wide range of complex and difficult problems related to functional design. Although a higher degree of design freedom beyond geometry has been enabled by AM, there are only very few computational design approaches in this new AM-enabled domain to design objects with tailored properties and functions. The objectives of this review paper are to provide an overview of recent additive manufacturing developments and current computer-aided design methodologies that can be applied to multimaterial, multiscale, multiform, and multifunctional AM technologies. The difficulties encountered in the computational design approaches are summarized and the future development needs are emphasized. In the paper, some present applications and future trends related to additive manufacturing technologies are also discussed

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

Functionally gradient tissue scaffold design and deposition path planning for bio-additive processes

A layer-based tissue scaffold is designed with heterogeneous internal architecture. The proposed layer-based design uses a bi-layer pattern of radial and spiral layer consecutively to generate functionally gradient porosity following the geometry of the scaffold. Medial region is constructed from medial axis and used as an internal geometric feature for each layer. The radial layers are generated with sub-region channels by connecting the boundaries of the medial region and the layer’s outer contour. Proper connections with allowable geometric properties are ensured by applying optimization algorithms. Iso-porosity regions are determined by dividing the sub-regions into pore cells. The combination of consecutive layers generates the pore cells with desired pore sizes. To ensure the fabrication of the designed scaffolds, both contours have been optimized for a continuous, interconnected, and smooth deposition path-planning. The proposed methodologies can generate the structure with gradient (linear or non-linear), variational or constant porosity that can provide localized control of variational porosity along the scaffold architecture. The designed porous structures can be fabricated using bio-additive fabrication processes