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

Exploring Model-Based Engineering Concepts for Additive Manufacturing

Robust geometry and tolerance representations are needed in additive manufacturing for precise part specification and interoperability with downstream activities such as manufacturing, inspection, and long-term archiving. A disconnection exists between process-independent part geometry and tolerances, and process-dependent information requirements for additive manufacturing. Existing and emerging standards for part geometry (ASTM AMF, 3MF, ISO 10303 STEP) and tolerances (ASME Y14) contain information related to the additive manufacturing process. Details of the standards will be discussed, how their use and improvement can benefit the additive manufacturing process, and their integration into the model-based engineering paradigm.Mechanical Engineerin

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

Large-Scale Additive Manufacturing Machine

This master thesis contains an overview of the additive manufacturing technology and building process of the large-scale Fused Deposition Modelling (FDM) additive manufacturing machine from the old Wafer Handling Diffusion machine. The thesis study is mainly focused on practical work and describes the techniques used during the project execution. The built machine can print large 3D prototypes from PLA plastic of three different colors. The final product of this thesis is a fully working large-scale AM machine made with the relatively small budget of 10.000 NOK which the university can use for educational purposes

Computer aided process planning for multi-axis CNC machining using feature free polygonal CAD models

This dissertation provides new methods for the general area of Computer Aided Process Planning, often referred to as CAPP. It specifically focuses on 3 challenging problems in the area of multi-axis CNC machining process using feature free polygonal CAD models. The first research problem involves a new method for the rapid machining of Multi-Surface Parts. These types of parts typically have different requirements for each surface, for example, surface finish, accuracy, or functionality. The CAPP algorithms developed for this problem ensure the complete rapid machining of multi surface parts by providing better setup orientations to machine each surface. The second research problem is related to a new method for discrete multi-axis CNC machining of part models using feature free polygonal CAD models. This problem specifically considers a generic 3-axis CNC machining process for which CAPP algorithms are developed. These algorithms allow the rapid machining of a wide variety of parts with higher geometric accuracy by enabling access to visible surfaces through the choice of appropriate machine tool configurations (i.e. number of axes). The third research problem addresses challenges with geometric singularities that can occur when 2D slice models are used in process planning. The conversion from CAD to slice model results in the loss of model surface information, the consequence of which could be suboptimal or incorrect process planning. The algorithms developed here facilitate transfer of complete surface geometry information from CAD to slice models. The work of this dissertation will aid in developing the next generation of CAPP tools and result in lower cost and more accurately machined components

Uniform Micro-Patterning of an Arbitrary Surface

According to the literature, creating specific micro-level patterns on some surfaces can significantly reduce friction. To this effect, a method is presented to create a regular pattern of micro-level indentations on any irregular surface. Creating a uniform pattern on a regular surface is possible using commercial CAD software, where regular surface is the surface obtained by extrusion or revolution of a 2D sketch along any curve. But, it is complicated and often incorrect for irregular surfaces. The thesis presents the approach followed to create parameterized regular patterns on arbitrary surfaces. Three different algorithms are presented, each achieving a progressively increased quality solution. The last and best method provides a set of points with their corresponding normals to the surface to enable the creation of the patterning feature. The algorithm reads an STL file, a format neutral output of any CAD software and implements the method on the approximated surface. Each facet surface upon which the pattern has to be created is sliced by planes at specific distances from each other. The intersections of the facets and the planes are calculated and chains are formed from the intersections in each plane. Points are interpolated at the required pitch in different chains formed at the intersection of a single plane and the facets. This procedure is repeated for each plane. Thus, a pattern of points of specified pitch distance that can be as low as microns can be generated. Given specifications of a machine, this method generates the X, Y, and Z translations and the axis rotation angles needed to generate a g-code specific to a micro-milling machine. This code can be used directly for any metal removing process that has to create micro-level indentations on an arbitrary surface. If instead, the features are protrusions on some irregular surface, then the resultant points obtained with the developed approach can be used to apply the pattern at each of the identified locations

Advanced Design for Additive Manufacturing: 3D Slicing and 2D Path Planning

Commercial 3D printers have been increasingly implemented in a variety of fields due to their quick production, simplicity of use, and cheap manufacturing. Software installed in these machines allows automatic production of components from computer-aided design (CAD) models with minimal human intervention. However, there are fewer options provided, with a limited range of materials, limited path patterns, and layer thicknesses. For fabricating metal functional parts, such as laser-based, electron beam-based, and arc-welding-based additive manufacturing (AM) machines, usually more careful process design requires in order to obtain components with the desired mechanical and material properties. Therefore, advanced design for additive manufacturing, particularly slicing and path planning, is necessary for AM experts. This chapter introduces recent achievements in slicing and path planning for AM process