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

A Method to Generate Exact Contour Files for Solid Freeform Fabrication

Existing methods to create contour files generate a polygonal approximation of the contours instead of an exact representation. This paper presents a method to generate exact contours from Constructive Solid Geometry (CSG) representations. The method preserves the accuracy of the contour files provided the primitives used to generate the CSG tree are polygonal or quadric objects. Due to the inclusion of quadric objects into the primitive set an additional effort to solve for the intersection points between two quadric curves is required. The paper also presents a method to convert piecewise quadratic contours to toggle point files for raster scanning solid freeform fabrication processes.Mechanical Engineerin

Electronic integrator for gyro rate output voltages

Circuit which integrates spacecraft gyro output voltages to provide analog position signals has been developed. Accurate integration is provided by all solid state system which uses no choppers and takes advantage of commercially available flight qualified components

Software Testbed for Selective Laser Sintering

Computer software plays an important role in the implementation of Solid Freeform Fabrication (SFF) technologies. This paper describes a software testbed for processing part geometry for a particular SFF technology, selective laser sintering (SLS), that is built around the separation of the slicing and rasterization operations to accommodate geometric information from a variety of sources. The paper also discusses the process control software being developed for a new high-temperat rkstation for SLS of metal powders. This program features a high-resolution data rmat, the ability to interpolate to achieve a desired resolution, and a menu-driven user interface with graphical feedback and process simulation capabilities.Mechanical Engineerin

MRI and clinical resolution of a suspected intracranial toxoplasma granuloma with medical treatment in a domestic short hair cat

A two-year-old cat was presented with a left paradoxical vestibular syndrome. MRI of the brain revealed an extra-axial homogenously contrast enhancing mass in the region of the left caudal cerebellar peduncle. Toxoplasma serology was consistent with active infection and the lesion was suspected to be a toxoplasma granuloma. Following eight weeks of tapering oral prednisolone and 11 weeks of oral clindamycin treatment, repeat MRI revealed resolution of the lesion. Eighteen months after initial diagnosis, the cat remained neurologically normal. Differential diagnoses for a solitary, extra-axial, contrast enhancing mass lesion in the feline brain should include toxoplasma granuloma, which can undergo MRI and clinical resolution with medical treatment

Scaling and singularities in the entrainment of globally-coupled oscillators

The onset of collective behavior in a population of globally coupled oscillators with randomly distributed frequencies is studied for phase dynamical models with arbitrary coupling. The population is described by a Fokker-Planck equation for the distribution of phases which includes the diffusive effect of noise in the oscillator frequencies. The bifurcation from the phase-incoherent state is analyzed using amplitude equations for the unstable modes with particular attention to the dependence of the nonlinearly saturated mode $|\alpha_\infty|$ on the linear growth rate $\gamma$. In general we find $|\alpha_\infty|\sim \sqrt{\gamma(\gamma+l^2D)}$ where $D$ is the diffusion coefficient and $l$ is the mode number of the unstable mode. The unusual $(\gamma+l^2D)$ factor arises from a singularity in the cubic term of the amplitude equation.Comment: 11 pages (Revtex); paper submitted to Phys. Rev. Let

Science and Applications Space Platform (SASP) End-to-End Data System Study

The capability of present technology and the Tracking and Data Relay Satellite System (TDRSS) to accommodate Science and Applications Space Platforms (SASP) payload user's requirements, maximum service to the user through optimization of the SASP Onboard Command and Data Management System, and the ability and availability of new technology to accommodate the evolution of SASP payloads were assessed. Key technology items identified to accommodate payloads on a SASP were onboard storage devices, multiplexers, and onboard data processors. The primary driver is the limited access to TDRSS for single access channels due to sharing with all the low Earth orbit spacecraft plus shuttle. Advantages of onboard data processing include long term storage of processed data until TRDSS is accessible, thus reducing the loss of data, eliminating large data processing tasks at the ground stations, and providing a more timely access to the data

Space shuttle entry and landing navigation analysis

A navigation system for the entry phase of a Space Shuttle mission which is an aided-inertial system which uses a Kalman filter to mix IMU data with data derived from external navigation aids is evaluated. A drag pseudo-measurement used during radio blackout is treated as an additional external aid. A comprehensive truth model with 101 states is formulated and used to generate detailed error budgets at several significant time points -- end-of-blackout, start of final approach, over runway threshold, and touchdown. Sensitivity curves illustrating the effect of variations in the size of individual error sources on navigation accuracy are presented. The sensitivity of the navigation system performance to filter modifications is analyzed. The projected overall performance is shown in the form of time histories of position and velocity error components. The detailed results are summarized and interpreted, and suggestions are made concerning possible software improvements

The spatial distribution and time evolution of impact-generated magnetic fields

The production of magnetic fields was revealed by laboratory hypervelocity impacts in easily vaporized targets. As quantified by pressure measurements, high frame-rate photography, and electrostatic probes, these impacts tend to produce large quantities of slightly ionized vapor, which is referred to as impact-generated plasma. Nonaligned electron density and temperature gradients within this plasma may lead to production of the observed magnetic fields. Past experiments were limited to measuring a single component of the impact-generated magnetic fields at only a few locations about the developing impact crater and consequently gave little information about the field production mechanism. To understand this mechanism, the techniques were extended to map the three components of the magnetic field both in space and time. By conducting many otherwise identical experiments with arrayed magnetic detectors, a preliminary 3-D picture was produced of impact-generated magnetic fields as they develop through time