scholarly journals Manufacturability Oriented Model Correction and Build Direction Optimization for Additive Manufacturing

2019 ◽  
Vol 142 (6) ◽  
Author(s):  
Erva Ulu ◽  
Nurcan Gecer Ulu ◽  
Walter Hsiao ◽  
Saigopal Nelaturi
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
3D Model ◽  
3D Models ◽  
Geometric Constraints ◽  
Feature Size ◽  
Printing Process ◽  
Model Correction ◽  
Process Characteristics ◽  
Orientation Optimization

Abstract We introduce a method to analyze and modify a shape to make it manufacturable for a given additive manufacturing (AM) process. Different AM technologies, process parameters, or materials introduce geometric constraints on what is manufacturable or not. Given an input 3D model and minimum printable feature size dictated by the manufacturing process characteristics and parameters, our algorithm generates a corrected geometry that is printable with the intended AM process. A key issue in model correction for manufacturability is the identification of critical features that are affected by the printing process. To address this challenge, we propose a topology aware approach to construct the allowable space for a print head to traverse during the 3D printing process. Combined with our build orientation optimization algorithm, the amount of modifications performed on the shape is kept at minimum while providing an accurate approximation of the as-manufactured part. We demonstrate our method on a variety of 3D models and validate it by 3D printing the results.

Algorithm to Reduce Leading and Lagging in Conformal Direct-Print

2018 ◽  
Vol 140 (10) ◽  
Author(s):  
Morteza Vatani ◽  
Faez Alkadi ◽  
Jae-Won Choi
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
3D Model ◽  
Three Dimensional ◽  
Motion Direction ◽  
B Spline ◽  
And Topology ◽  
Printing System ◽  
3D Printed ◽  
Printed Patterns

A novel additive manufacturing algorithm was developed to increase the consistency of three-dimensional (3D) printed curvilinear or conformal patterns on freeform surfaces. The algorithm dynamically and locally compensates the nozzle location with respect to the pattern geometry, motion direction, and topology of the substrate to minimize lagging or leading during conformal printing. The printing algorithm was implemented in an existing 3D printing system that consists of an extrusion-based dispensing module and an XYZ-stage. A dispensing head is fixed on a Z-axis and moves vertically, while the substrate is installed on an XY-stage and moves in the x–y plane. The printing algorithm approximates the printed pattern using nonuniform rational B-spline (NURBS) curves translated directly from a 3D model. Results showed that the proposed printing algorithm increases the consistency in the width of the printed patterns. It is envisioned that the proposed algorithm can facilitate nonplanar 3D printing using common and commercially available Cartesian-type 3D printing systems.

Channel design for 3D models with applications in powder-bed additive manufacturing

2019 ◽  
Vol 25 (9) ◽  
pp. 1536-1544
Author(s):  
Xiangzhi Wei ◽  
Xianda Li ◽  
Shanshan Wen ◽  
Yu Zheng ◽  
Yaobin Tian
Keyword(s):  
Additive Manufacturing ◽  
3D Model ◽  
3D Models ◽  
Linear Constraints ◽  
Channel Design ◽  
Channel Network ◽  
Content Type ◽  
Powder Bed ◽  
Shortest Network ◽  
Manufacturing Techniques

Purpose For any 3D model with chambers to be fabricated in powder-bed additive manufacturing processes such as SLM and SLS, powders are trapped in the chambers of the finished model. This paper aims to design a shortest network with the least number of outlets for efficiently leaking the trapped powders. Design/methodology/approach This paper proposes a nonlinear objective with linear constraints for solving the channel design problem and a particle swarm optimization algorithm to solve the nonlinear system. Findings Structural optimization for the channel network leads to fairly short channels in the interior of the 3D models and very few outlets on the model surface, which achieves the cleaning of the powders while causing almost the least changes to the model. Originality/value This paper reveals the NP-harness of computing the shortest channel network with the least number of outlets. The proposed approach helps the design of lightweight models using the powder-bed additive manufacturing techniques.

A Heuristic Scaling Strategy for Multi-Robot Cooperative Three-Dimensional Printing

2020 ◽  
Vol 20 (4) ◽  
Author(s):  
Laxmi Poudel ◽  
Chandler Blair ◽  
Jace McPherson ◽  
Zhenghui Sha ◽  
Wenchao Zhou
Keyword(s):  
3D Printing ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Evaluation Framework ◽  
Geometric Constraints ◽  
Mathematical Representation ◽  
Printing Process ◽  
Fused Deposition ◽  
3D Printers ◽  
Printing Time

Abstract While three-dimensional (3D) printing has been making significant strides over the past decades, it still trails behind mainstream manufacturing due to its lack of scalability in both print size and print speed. Cooperative 3D printing (C3DP) is an emerging technology that holds the promise to mitigate both of these issues by having a swarm of printhead-carrying mobile robots working together to finish a single print job cooperatively. In our previous work, we have developed a chunk-based printing strategy to enable the cooperative 3D printing with two fused deposition modeling (FDM) mobile 3D printers, which allows each of them to print one chunk at a time without interfering with the other and the printed part. In this paper, we present a novel method in discretizing the continuous 3D printing process, where the desired part is discretized into chunks, resulting in multi-stage 3D printing process. In addition, the key contribution of this study is the first working scaling strategy for cooperative 3D printing based on simple heuristics, called scalable parallel arrays of robots for 3DP (SPAR3), which enables many mobile 3D printers to work together to reduce the total printing time for large prints. In order to evaluate the performance of the printing strategy, a framework is developed based on directed dependency tree (DDT), which provides a mathematical and graphical description of dependency relationships and sequence of printing tasks. The graph-based framework can be used to estimate the total print time for a given print strategy. Along with the time evaluation metric, the developed framework provides us with a mathematical representation of geometric constraints that are temporospatially dynamic and need to be satisfied in order to achieve collision-free printing for any C3DP strategy. The DDT-based evaluation framework is then used to evaluate the proposed SPAR3 strategy. The results validate the SPAR3 as a collision-free strategy that can significantly shorten the printing time (about 11 times faster with 16 robots for the demonstrated examples) in comparison with the traditional 3D printing with single printhead.

scholarly journals Possibilities of Preoperative Medical Models Made by 3D Printing or Additive Manufacturing

2016 ◽  
Vol 2016 ◽  
pp. 1-6 ◽  
Author(s):  
Mika Salmi
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
3D Modeling ◽  
Mechanical Engineering ◽  
3D Model ◽  
Model Reconstruction ◽  
3D Model Reconstruction ◽  
Wide Range ◽  
Printing Processes ◽  
Binder Jetting

Most of the 3D printing applications of preoperative models have been focused on dental and craniomaxillofacial area. The purpose of this paper is to demonstrate the possibilities in other application areas and give examples of the current possibilities. The approach was to communicate with the surgeons with different fields about their needs related preoperative models and try to produce preoperative models that satisfy those needs. Ten different kinds of examples of possibilities were selected to be shown in this paper and aspects related imaging, 3D model reconstruction, 3D modeling, and 3D printing were presented. Examples were heart, ankle, backbone, knee, and pelvis with different processes and materials. Software types required were Osirix, 3Data Expert, and Rhinoceros. Different 3D printing processes were binder jetting and material extrusion. This paper presents a wide range of possibilities related to 3D printing of preoperative models. Surgeons should be aware of the new possibilities and in most cases help from mechanical engineering side is needed.

scholarly journals ANIMATED ADDITIVE MANUFACTURING Designing Dynamic Exhibits with 3D Printing & Pixel Displays

2021 ◽  
Author(s):  
◽  
Lakjith Manapaya Weeratunge
Keyword(s):  
Additive Manufacturing ◽  
Video Games ◽  
3D Printing ◽  
Digital Information ◽  
Complex Motion ◽  
High Demand ◽  
Printing Process ◽  
Wear And Tear ◽  
Display Technology ◽  
Realistic Images

<p>Physical moving parts are prone to wear and tear. A pixel display can manifest complex motion and realistic images in full colour offering a form of tangibly while being less likely to suffer from wear and tear however, it remains restricted to 2D surfaces. The recent development in voxel-based printing (voxel = 3D pixel) allows multi-material and multi-colour 3D printing to transform images into physical objects. However, during the printing process the capacity to change the pixels colour and position in the future are lost, effectively fusing the digital information. The high demand for immersive experiences in video games, films, museums and interactive products are omnipresent. The combination of pixel display technology and multi-material 3D printing is a potential avenue to create immersive experiences to feed this high demand.</p>

Rapid Prototyping Technology for Special Pressure Vessels

2018 ◽  
Vol 919 ◽  
pp. 222-229
Author(s):  
Jiří Šafka ◽  
Filip Veselka ◽  
Martin Lachman ◽  
Michal Ackermann
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
3D Model ◽  
Selective Laser Sintering ◽  
Pressure Vessels ◽  
Pressure Test ◽  
Polypropylene Material ◽  
3D Printed ◽  
Manufacturing Technologies ◽  
Made In

The article deals with the topic of 3D printing of pressure vessels and their testing. The main focus of the research was on a 3D model of the pressure vessel, which was originally designed for a student formula racing car project. The described virtual 3D model was designed with regard to 3D printing. The physical model was manufactured using several additive manufacturing technologies. The first technology was FDM using ULTEM 1010 material. The next technology was SLS (Selective Laser Sintering) using polyamide materials (PA3200GF and PA2220). The last technology was SLA (Stereolithography) using a polypropylene material (Durable). Experimental evaluation of the vessels was carried out by a pressure test, which verified the compactness of the 3D printed parts and their possible porosity. At the end of the article, a comparison of each printed model is made in terms of their final price and weight, together with pressure and thermal resistance.

scholarly journals The Influence of Different Slicer Software on 3d Printing Products Accuracy and Surface Roughness

2021 ◽  
Vol 12 (2) ◽  
pp. 371-380
Author(s):  
Sally Cahyati ◽  
◽  
Haris Risqy Aziz
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
3D Printing ◽  
3D Model ◽  
High Surface ◽  
3D Printer ◽  
Layer By Layer ◽  
Additive Manufacturing Technology ◽  
Printing Machine

Rapid Prototyping (RP) is a manufacturing process that produces a 3D model CAD to be a real product rapidly by using additive manufacturing technology. In this case, the product will print layer by layer uses a 3D printer machine. The 3D printer requires slicer software to convert CAD data into data that a 3D printer machine can read. Research is done to analyze the effect of three kinds of slicer software on 3D printing objects on the accuracy and surface roughness of the product. The 3D model CAD is sliced using three different slicer software, namely Ideamaker, Repetier Host, and Cura. The slice model result from each slicer will be printed on a 3D printer machine with the same process parameters to be compared. Then the product's dimensional and surface roughness will be measured to determine the effect of each slicer on product quality. The best quality of the product reflected the most suitable slicer software for the 3D printing machine that used. The best results achieved by Cura slicer because it has resulted in small dimensional deviations (max 0,0308±0,0079) and stabile high surface roughness of the product (max 1,585+059).

scholarly journals Comparison between Tests and Simulations Regarding Bending Resistance of 3D Printed PLA Structures

Polymers ◽  
2021 ◽  
Vol 13 (24) ◽  
pp. 4371
Author(s):  
Dorin-Ioan Catana ◽  
Mihai-Alin Pop ◽  
Denisa-Iulia Brus
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Process Parameters ◽  
Bending Stress ◽  
Test Results ◽  
Printing Process ◽  
Simulation Process ◽  
Bending Resistance ◽  
3D Printed

Additive manufacturing is one of the technologies that is beginning to be used in new fields of parts production, but it is also a technology that is constantly evolving, due to the advances made by researchers and printing equipment. The paper presents how, by using the simulation process, the geometry of the 3D printed structures from PLA and PLA-Glass was optimized at the bending stress. The optimization aimed to reduce the consumption of filament (material) simultaneously with an increase in the bending resistance. In addition, this paper demonstrates that the simulation process can only be applied with good results to 3D printed structures when their mechanical properties are known. The inconsistency of printing process parameters makes the 3D printed structures not homogeneous and, consequently, the occurrence of errors between the test results and those of simulations become natural and acceptable. The mechanical properties depend on the values of the printing process parameters and the printing equipment because, in the case of 3D printing, it is necessary for each combination of parameters to determine their mechanical properties through specific tests.

Design Modification of Additive Manufacturing Parts Using Texture Information of 3D Model

2019 ◽  
Vol 825 ◽  
pp. 19-30
Author(s):  
Tsung Chien Wu ◽  
Jiing Yih Lai ◽  
Yu Wen Tseng ◽  
Chao Yaug Liao ◽  
Ju Yi Lee
Keyword(s):  
Additive Manufacturing ◽  
3D Model ◽  
Three Dimensional ◽  
Texture Mapping ◽  
3D Models ◽  
Surface Shape ◽  
Design Features ◽  
Design Modification ◽  
Texture Information ◽  
Triangular Model

Additive manufacturing (AM) has been commonly used for the prototyping of three-dimensional (3D) models. The input model of the AM technology is a triangular model representing the surface shape of an object. The design features on a triangular model are generally not clear as the vertices are irregularly distributed. If design modification is necessary, it is difficult to segment and extract the meshes from the model. The objective of this study is to propose a method for extracting the design features on an object model by using the texture information. A 3D color model including a triangular model representing the object shape and a texture map describing the object texture is employed. The 3D model is generated by using a set of object images captured from different views surrounding the object. A texture mapping algorithm is then employed to generate the texture map corresponding to the 3D model. With both meshes and texture displayed in a texture mode, a region extraction technique is employed to extract the design features. All parts separated can then be fabricated with an AM machine, and assembled for checking the feasibility of design modification. Several products are employed to demonstrate the feasibility of the proposed technique.

Manufacturability Feedback and Model Correction for Additive Manufacturing

2014 ◽  
Author(s):  
Saigopal Nelaturi ◽  
Walter Kim ◽  
Arvind Rangarajan ◽  
Tolga Kurtoglu
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Medial Axis ◽  
Three Dimensional ◽  
Medial Axis Transform ◽  
Specific Design ◽  
Model Correction ◽  
Geometric Deviations ◽  
Physical Limitations ◽  
Printing Processes

Additive manufacturing, or 3d printing, is the process of building three dimensional solid shapes by accumulating material laid out in sectional layers. Additive manufacturing has been recognized for enabling production of complex custom parts that are difficult to manufacture otherwise. However, the dependence on build orientation and physical limitations of printing processes invariably lead to geometric deviations between manufactured and designed shapes that are usually evaluated after manufacture. In this paper, we formalize the measurement of such deviations in terms of a printability map that simulates the printing process and partitions each printed layer into disjoint regions with distinct local measures of size. We show that manufacturing capabilities such as printing resolution, and material specific design recommendations such as minimal feature sizes may be coupled in the printability map to evaluate expected deviations before manufacture. Furthermore, we demonstrate how partitions with size measures below required resolutions may be modified using properties of the medial axis transform, and use the corrected printability map to construct a representation of the manufactured model. We conclude by discussing several applications of the printability map for additive manufacturing.

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