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
