Multi-Direction Slicing for Layered Manufacturing

2000 ◽  
Author(s):  
Prabhjot Singh ◽  
Debasish Dutta
Keyword(s):  
Surface Quality ◽  
Layered Manufacturing ◽  
Support Structure ◽  
Surface Accuracy ◽  
Build Time ◽  
Limited Surface

Abstract Parts made by Layered Manufacturing (LM) have a limited surface accuracy and their build time is often long due to the deposition of sacrificial support structure. However, LM machines with an ability to deposit along multiple directions can improve upon the surface quality and reduce the support volume. In this paper we consider multi-directional slicing, present algorithms and implemented examples.

Multi-Direction Slicing for Layered Manufacturing

2001 ◽  
Vol 1 (2) ◽  
pp. 129-142 ◽  
Author(s):  
Prabhjot Singh ◽  
Debasish Dutta
Keyword(s):  
Surface Quality ◽  
Layered Manufacturing ◽  
Support Structure ◽  
Surface Accuracy ◽  
Build Time ◽  
Key Issues ◽  
Limited Surface ◽  
Task Framework

Parts made by Layered Manufacturing (LM) have a limited surface accuracy and their build time is often long due to the deposition of sacrificial support structure. However, LM machines with an ability to deposit along multiple directions can improve upon the surface quality and reduce the support volume. In this paper we analyze the problem of multi-direction slicing. This analysis addresses the questions: How much of a part should be made along a particular direction and why. The strategy used in multi-direction slicing is to progressively decompose the part into sub-volumes, each of which can be completely built along a certain direction. Key issues are identified and a task framework for multidirection slicing is proposed. Algorithms and implemented examples are presented.

Building Sequence of Boundary Model in Layered Manufacturing

2005 ◽  
Author(s):  
Kunnayut Eiamsa-ard ◽  
Jianzhong Ruan ◽  
Lan Ren ◽  
F. W. Liou
Keyword(s):  
Manufacturing Process ◽  
Layered Manufacturing ◽  
Support Structures ◽  
Metal Parts ◽  
Rotation Axes ◽  
Build Time ◽  
Lamp System ◽  
Boundary Model ◽  
Limited Surface ◽  
Part Model

Even though building functional metal parts directly from CAD files has been the focus of many researches for many years, parts made by Layered Manufacturing (LM) have limited surface accuracy and long build time due to the sacrificial support structures. The Multi-Axis Laser Aided Manufacturing Process (LAMP) system improves build time by adding two more rotation axes to the system in order to reduce the support structures. The strategy to decompose the part model to sub-volumes or cells and the algorithm to arrange the deposition of those cells are discussed. The problems and questions of how much material should be deposited along the determined directions are also addressed in this paper.

Feature Based Fabrication in Layered Manufacturing

1999 ◽  
Vol 123 (3) ◽  
pp. 337-345 ◽  
Author(s):  
Xiaoping Qian ◽  
Debasish Dutta
Keyword(s):  
Surface Quality ◽  
Material Properties ◽  
Layered Manufacturing ◽  
Feature Interaction ◽  
Interaction Volume ◽  
Curvature Effects ◽  
Volume Decomposition ◽  
Build Time ◽  
Feature Based ◽  
Novel Concept

To address the conflicting requirements between holding specified surface quality and decreasing build time in layered manufacturing, we present a feature-based fabrication methodology whereby the curvature effects are localized within each decomposed volume. However, staircase interaction between the boundaries of the decomposed neighboring volumes creates geometric incompatibility for deposition, which further results in undesired material properties. This paper proposes a novel concept, feature interaction volume, to eliminate the staircase interaction. Based on this concept, a feature based volume decomposition algorithm is developed. This algorithm enables each decomposed volume to be fabricated independently and compatibly. Implementation and example results are also presented.

Some Geometric Techniques to Reduce Build Time in LOM

2001 ◽  
Author(s):  
Pang King Wah ◽  
Ajay Joneja
Keyword(s):  
Layered Manufacturing ◽  
Manufacturing Technology ◽  
Rectangular Grid ◽  
Geometric Properties ◽  
Traditional Technique ◽  
Laminated Object Manufacturing ◽  
Build Time ◽  
Waste Removal ◽  
Geometric Techniques

Abstract We propose a new CAPP system for the layered manufacturing technology of LOM (laminated object manufacturing). The traditional technique of building wastes much effort and time in generation of rectangular grid patterns to the exterior of the model to facilitate waste removal. In the proposed approach, several geometric properties of the model are exploited to dramatically reduce the waste removal grids. This in turn leads to reduced build-time, with no effect on the build quality. An integrated CAPP system incorporating these ideas has been developed, and an example part is presented to show how the system performs.

Offset Slices for Multidirection Layered Deposition

2008 ◽  
Vol 130 (1) ◽  
Author(s):  
Prabhjot Singh ◽  
Debasish Dutta
Keyword(s):  
Layered Manufacturing ◽  
Thin Layers ◽  
Post Processing ◽  
Build Time ◽  
Overhang Angle ◽  
Task Framework

Layered Manufacturing (LM) techniques build a part by adding thin layers of material. In this process, overhangs need to be supported by sacrificial supports, resulting in an increase in the build time, wastage of material, and costly post-processing. Metal-based LM machines with the capability to deposit material along multiple directions resolve most of the above problems. Importantly, these machines can deposit nonplanar slices. In this paper, we study such slices and present a task framework for their use with multidirectional layered deposition machines. The aim of the analysis is to identify part subvolumes that can be built using nonplanar slices for a process-dependent overhang angle. Solution methodologies for 2D, extruded parts, and general 3D parts are presented. Algorithms and illustrative example parts are included.

Parallel non-dominated sorting genetic algorithm-II for optimal part deposition orientation in additive manufacturing based on functional features

2017 ◽  
Vol 232 (19) ◽  
pp. 3384-3395 ◽  
Author(s):  
Renkai Huang ◽  
Ning Dai ◽  
Dawei Li ◽  
Xiaosheng Cheng ◽  
Hao Liu ◽  
...  
Keyword(s):  
Genetic Algorithm ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Surface Finish ◽  
Fused Deposition Modeling ◽  
Fused Deposition ◽  
Industrial Grade ◽  
Build Time ◽  
Functional Features

Surface finish, especially the surface finish of functional features, and build time are two important concerns in additive manufacturing. A suitable part deposition orientation can enhance the surface quality of functional features and reduce the build time. This article proposes a novel method to obtain an optimum part deposition orientation for industrial-grade 3D printing based on fused deposition modeling process by considering two objective functions at a time, namely adaptive feature roughness (the weighted sum of all feature roughnesses) and build time. First, mesh segmentation and level classification of features are carried out. Then, models for evaluation of adaptive feature roughness and build time are established. Finally, a non-dominated sorting genetic algorithm-II based on Compute Unified Device Architecture is used to obtain the Pareto-optimal set. The feasible of the algorithm is evaluated on several examples. Results demonstrate that the proposed parallel algorithm obtains a limiting solution that enhances the surface quality of functional features significantly and reduces average running time by 94.8% compared with the traditional genetic algorithm.

Tolerance-Based Layer Setup Optimization for Layered Manufacturing

2010 ◽  
Author(s):  
Jack Szu-Shen Chen ◽  
Hsi-Yung Steve Feng
Keyword(s):  
Layer Thickness ◽  
Maximum Error ◽  
Layered Manufacturing ◽  
Design Model ◽  
Maximum Efficiency ◽  
Original Design ◽  
Allowable Deviation ◽  
Number Of Layers ◽  
Build Time ◽  
Model Geometry

This paper introduces a new tolerance-based method to generate the optimum layer setup required to build layered manufacturing (LM) end-user parts for maximized efficiency. To achieve this, the deviation between the final polished LM part geometry and the original design model are formulated and controlled. Maximized layer thicknesses are then realized through optimization of each layer position with respect to the design and final geometry and maximization of the allowable deviation for each layer, which consequently leads to minimization of the build time. Current LM layer setup methods do not take into account of the final part during layer setup generation, rendering layer thickness selection to operator-deemed-best. Without the ability to predict the final geometry and to optimize the layer setup accordingly, layer thickness selection is often overly conservative, causing more layers than necessary to be used. Since the LM build time increases exponentially with an increase in the number of layers, efficiency is greatly reduced with conservative layer setup. To achieve maximum efficiency, this paper proposes a new method based on error compensation and minimization to solve for the optimum layer setup necessary to allow the resulting final physical part to reliably approximate the design model geometry according to a user specified tolerance limit. Case studies have been performed in order to validate that the proposed method is able to minimize the number of layers for constructing an LM part while controlling the maximum error for tolerance conformance.

Pre-Processing of Heterogeneous Objects for Layered Manufacturing

2001 ◽  
Author(s):  
Ki-Hoon Shin ◽  
Debasish Dutta
Keyword(s):  
Tool Path ◽  
New Technology ◽  
Three Dimensional ◽  
Layered Manufacturing ◽  
Pattern Generation ◽  
Geometric Features ◽  
Adaptive Slicing ◽  
Heterogeneous Objects ◽  
Build Time ◽  
Material Information

Abstract Layered manufacturing (LM) is emerging as a new technology that enables fabrication of three dimensional heterogeneous objects (such as Multi-materials and Functionally Gradient Materials). The steps for fabricating heterogeneous objects include model representation and material process planning. This paper introduces a method for processing the material information. It includes pre-processing (discretization), orientation (build direction selection), and adaptive slicing of heterogeneous objects. The discretization process converts all material information inside a heterogeneous object to material features like geometric features, thus it makes it possible to determine build direction by estimating build time based on geometric features and material features. It also allows adaptive slicing of heterogeneous objects to minimize surface finish and material resolution error. In addition, tool path planning can be simplified to fill pattern generation. Examples are shown.

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