Build Direction for 3D Heterogeneous Object in Additive Manufacturing

2013 ◽  
Author(s):  
AKM B. Khoda
Keyword(s):  
Additive Manufacturing ◽  
Object A ◽  
Support Materials ◽  
Part Quality ◽  
Material Deposition ◽  
Heterogeneous Object ◽  
Build Time ◽  
Functional Object ◽  
Continuous Material ◽  
Internal Architecture

Build direction in additive manufacturing is mostly determined considering the time, support materials and surface finish of the fabricated part. However, internal architecture of the part cannot be ignored in porous functional object design. Especially, heterogeneous object with internal features can be decomposed into 2D heterogeneous slices with island in which each island represent associated feature’s properties different from the base. Continuous material deposition in such multi-feature/multi-contour slices can be intervened by frequent directional changes intersecting those islands and can affect the build time and part quality. This research aims to minimize such intervention in the decomposed slices of heterogeneous object. A computational algorithm is proposed to quantify the build direction considering the location and alignment of the internal feature which can maximize the homogeneous slices generated from a heterogeneous object. The proposed methodology is illustrated by an example in this work. The algorithm can provide better control over the internal architecture design by selecting the best build direction for the heterogeneous object.

Build Direction for Improved Process Plan in Multi-Material Additive Manufacturing

2014 ◽  
Author(s):  
Bashir Khoda
Keyword(s):  
Additive Manufacturing ◽  
Material Object ◽  
Layer By Layer ◽  
Multiple Features ◽  
Process Plan ◽  
Material Deposition ◽  
Heterogeneous Object ◽  
Build Time ◽  
Material Process ◽  
Manufacturing Techniques

Current additive manufacturing processes mostly accustomed with mono-material process plan algorithm to build object layer by layer. However, building a multi-material or heterogeneous object with an additive manufacturing system is fairly new but emerging concept. Unlike mono-material object, heterogeneous object contains multiple features or inhomogeneous architecture and can be decomposed into two dimensional heterogeneous layers with islands where each island represents associated feature’s properties. The material deposition path-plan in such multi-feature/multi-contour layers requires more resources and may affect the part integrity, quality, and build time. A novel framework is presented in this paper to determine the optimum build direction for heterogeneous object by differentiating the slice based on the resources requirement. Slices are bundled based on the heterogeneity and the effect of build directions are quantified considering the feature characteristics and manufacturing attributes. The proposed methodology is illustrated by examples with 50% or more homogeneous slices along the optimum build direction. The outcome would certainly benefit the process plan for multi-material additive manufacturing techniques.

scholarly journals On the Impact of Additive Manufacturing Processes Complexity on Modelling

2021 ◽  
Vol 11 (16) ◽  
pp. 7743
Author(s):  
Panagiotis Stavropoulos ◽  
Panagis Foteinopoulos ◽  
Alexios Papapacharalampopoulos
Keyword(s):  
Additive Manufacturing ◽  
Performance Indicators ◽  
Part Quality ◽  
Build Time ◽  
Modelling Techniques ◽  
And Performance ◽  
The Many ◽  
Process Complexity ◽  
The Impact ◽  
Am Processes

The interest in additive manufacturing (AM) processes is constantly increasing due to the many advantages they offer. To this end, a variety of modelling techniques for the plethora of the AM mechanisms has been proposed. However, the process modelling complexity, a term that can be used in order to define the level of detail of the simulations, has not been clearly addressed so far. In particular, one important aspect that is common in all the AM processes is the movement of the head, which directly affects part quality and build time. The knowledge of the entire progression of the phenomenon is a key aspect for the optimization of the path as well as the speed evolution in time of the head. In this study, a metamodeling framework for AM is presented, aiming to increase the practicality of simulations that investigate the effect of the movement of the head on part quality. The existing AM process groups have been classified based on three parameters/axes: temperature of the process, complexity, and part size, where the complexity has been modelled using a dedicated heuristic metric, based on entropy. To achieve this, a discretized version of the processes implicated variables has been developed, introducing three types of variable: process parameters, key modeling variables and performance indicators. This can lead to an enhanced roadmap for the significance of the variables and the interpretation and use of the various models. The utilized spectrum of AM processes is discussed with respect to the modelling types, namely theoretical/computational and experimental/empirical.

scholarly journals Determination of optimal build orientation for additive manufacturing using Muirhead mean and prioritised average operators

2019 ◽  
Vol 30 (8) ◽  
pp. 3015-3034 ◽  
Author(s):  
Yuchu Qin ◽  
Qunfen Qi ◽  
Paul J. Scott ◽  
Xiangqian Jiang
Keyword(s):  
Additive Manufacturing ◽  
Fuzzy Decision ◽  
Decision Matrix ◽  
Build Orientation ◽  
Part Quality ◽  
Determination Process ◽  
Build Time ◽  
Finite Set ◽  
Multi Attribute Decision Making

Abstract Build orientation determination is one of the essential process planning tasks in additive manufacturing since it has crucial effects on the part quality, post-processing, build time and cost, etc. This paper introduces a method based on fuzzy multi-attribute decision making to determine the optimal build orientation from a finite set of alternatives. The determination process includes two major steps. In the first step, attributes that are considered in the determination and heterogeneous relationships of which are firstly identified. A fuzzy decision matrix is then constructed and normalised based on the values of the identified attributes, which are quantified by a set of fuzzy numbers. In the second step, two fuzzy number aggregation operators are developed to aggregate the fuzzy information in the normalised matrix. By comparing the aggregation results, a ranking of all alternative build orientations can then be generated. Two determination examples are used to demonstrate the working process of the proposed method. Qualitative and quantitative comparisons between the proposed method and other methods are carried out to demonstrate its feasibility, effectiveness, and advantages.

Automated Planning for Robotic Multi-Resolution Additive Manufacturing

2021 ◽  
pp. 1-18
Author(s):  
Prahar Bhatt ◽  
Ashish Kulkarni ◽  
Rishi K. Malhan ◽  
Brual Shah ◽  
Yeo Jung Yoon ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Surface Quality ◽  
Computationally Efficient ◽  
Efficient Manner ◽  
Material Extrusion ◽  
Material Deposition ◽  
Build Time ◽  
Planning Algorithm ◽  
Path Planning Algorithm

Abstract Conventional material extrusion additive manufacturing (AM) processes require the user to make a trade-off between surface quality and build time of the part. The use of a large bead filament deposition can speed up the build process; however, it leads to surfaces with high roughness due to the stair-stepping effect. The surface quality can be improved by using a small bead filament deposition, which in turn increases the build time of the part. We present a new approach incorporating hybrid multi-resolution layers in material extrusion additive manufacturing to provide excellent surface quality without increasing the build time. Our slicing algorithm generates planar layers with large filament to fill the interior regions in less time. The generated exterior layers are conformal and use small filament to reduce the stair-stepping effect and improve surface quality. We also present a path planning algorithm to build parts with a single manipulator using a multi-nozzle extrusion tool. The path planning algorithm generates a smooth material deposition path by avoiding collision between the tool and the already built layers. It reduces the collision checks and performs collision detection in a computationally efficient manner. We build five parts to validate our approach and illustrate the benefits of multi-resolution AM.

scholarly journals Search for the Optimal Build Direction in Additive Manufacturing Technologies: A Review

2020 ◽  
Vol 4 (3) ◽  
pp. 71 ◽  
Author(s):  
Luca Di Angelo ◽  
Paolo Di Stefano ◽  
Emanuele Guardiani
Keyword(s):  
Additive Manufacturing ◽  
Optimization Techniques ◽  
Manufacturing Cost ◽  
Layer By Layer ◽  
Part Quality ◽  
Advantages And Disadvantages ◽  
Build Time ◽  
Set Up ◽  
Manufacturing Technologies ◽  
The Cost

By additive manufacturing technologies, an object is produced deposing material layer by layer. The piece grows along the build direction, which is one of the main manufacturing parameters of Additive Manufacturing (AM) technologies to be set-up. This process parameter affects the cost, quality, and other important properties of the manufactured object. In this paper, the Objective Functions (OFs), presented in the literature for the search of the optimal build direction, are considered and reviewed. The following OFs are discussed: part quality, surface quality, support structure, build time, manufacturing cost, and mechanical properties. All of them are distinguished factors that are affected by build direction. In the first part of the paper, a collection of the most significant published methods for the estimation of the factors that most influence the build direction is presented. In the second part, a summary of the optimization techniques adopted from the reviewed papers is presented. Finally, the advantages and disadvantages are briefly discussed and some possible new fields of exploration are proposed.

scholarly journals Adaptive Slicing in Additive Manufacturing Process Using a Modified Boundary Octree Data Structure

2015 ◽  
Vol 137 (1) ◽  
Author(s):  
Nandkumar Siraskar ◽  
Ratnadeep Paul ◽  
Sam Anand
Keyword(s):  
Data Structure ◽  
Additive Manufacturing ◽  
Layer By Layer ◽  
Adaptive Slicing ◽  
Stl File ◽  
Part Quality ◽  
Part Geometry ◽  
Build Time ◽  
Part Surface ◽  
Am Processes

In additive manufacturing (AM) processes, the layer-by-layer fabrication leads to a staircase error resulting in dimensional inaccuracies in the part surface. Using thinner slices reduces the staircase error and improves part accuracy but also increases the number of layers and the build time for manufacturing the part. Another approach called adaptive slicing uses slices of varying thicknesses based on the part geometry to build the part. A new algorithm to compute adaptive slice thicknesses using octree data structure is presented in this study. This method, termed as modified boundary octree data structure (MBODS) algorithm, is used to convert the stereolithography (STL) file of an object to an octree data structure based on the part's geometry, the machine parameters, and a user defined tolerance value. A subsequent algorithm computes the variable slice thicknesses using the MBODS representation of the part and virtually manufactures the part using these calculated slice thicknesses. Points sampled from the virtually manufactured part are inspected to evaluate the volumetric, profile, and cylindricity part errors. The MBODS based slicing algorithm is validated by comparing it with the uniform slicing approach using various slice thicknesses for different parts. The developed MBODS algorithm is observed to be more effective in improving the part quality while using lesser number of slices.

Build Time Analysis of Additive Manufacturing for Next Generation SLS Systems

2020 ◽  
Author(s):  
Michael Machado ◽  
Raul Fangueiro ◽  
Daniel Barros ◽  
Luís Nobre ◽  
João Bessa ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Sintering ◽  
Material Point ◽  
Point Of View ◽  
Efficient Production ◽  
Robust Solution ◽  
Functional Product ◽  
Build Time ◽  
Consistent Solution ◽  
Production Solutions

Abstract With the recent advances in the additive manufacturing (AM) production technologies, AM is becoming more common in today’s industry, nowadays is a normal practice to use this solution either to test a new prototype or to manufacture a functional product. The increase application is mainly due to significant developments in the production solutions of the AM. These recent developments are resulting in an increase search for new and more efficient production solutions. This search is always focused in producing more efficiently, with a greater variety of materials and produce part with better quality and proprieties. From an industrial point of view, one of the types of additive manufacturing that is increasing the percentage of use is the selective laser sintering (SLS) technologies. Although this process was first used in the mid-80’s, it has shown great developments in the recent years. This evolution of the process allowed it to become a solid solution even if it is highly time consuming, especially when compared with other types of addictive manufacturing. From the several aspects that make the SLS a robust solution is the fact that it offers a consistent solution to produce high complex part with good mechanical properties, and also the ability to use many core materials, from polymers, metal alloy, ceramics or even composites materials. Due to the fact that the production of part using SLS technologies takes a long time, shows the relevance to study the entire process in order to quantify the time spent in each stage a very important step. This study can be conducted with two major goals, in one hand to be able to predict the build time needed to complete a predetermined task, and in other hand, to improve the overall efficiency of the process based on the knowledge acquired in the previous analysis. These two aspects are important because they allow the machine operator to choose the production plan more carefully and also to know all the parameters of the process to make it more efficient. In this paper will be presented a survey of the major stages of a SLS process in order to quantify the time consumed in each one of the stages, and if possible, determine solution to reduce the time spent. To better understand the topic the paper will be divided according to the proprieties and time consumed in each of the elements of the process. In other words, it will be divided accordingly to a machine, laser and material point of view. Furthermore, this paper will be focused in the SLS process and the productions based in a polymeric powder, therefore also containing aspects related to the power source used.

Trajectory Planning for Conformal 3D Printing Using Non-Planar Layers

2018 ◽  
Author(s):  
Aniruddha V. Shembekar ◽  
Yeo Jung Yoon ◽  
Alec Kanyuck ◽  
Satyandra K. Gupta
Keyword(s):  
Additive Manufacturing ◽  
Trajectory Planning ◽  
Industrial Robots ◽  
Complex Geometries ◽  
Robot Arm ◽  
Joint Movement ◽  
Tool Orientation ◽  
3D Objects ◽  
Planar Surfaces ◽  
Build Time

Additive manufacturing (AM) technologies have been widely used to fabricate 3D objects quickly and cost-effectively. However, building parts consisting of complex geometries with multiple curvatures can be a challenging process for the traditional AM system whose capability is restricted to planar-layered printing. Using 6-DOF industrial robots for AM overcomes this limitation by allowing materials to deposit on non-planar surfaces with desired tool orientation. In this paper, we present collision-free trajectory planning for printing using non-planar deposition. Trajectory parameters subject to surface curvature are properly controlled to avoid any collision with printing surface. We have implemented our approach by using a 6-DOF robot arm. The complex 3D structures with various curvatures were successfully fabricated, while avoiding any failures in joint movement, holding comparable build time and completing with a satisfactory surface finish.

scholarly journals DECOMPOSITION ALGORITHM FOR TOOL PATH PLANNING FOR WIRE-ARC ADDITIVE MANUFACTURING

2018 ◽  
Vol Vol.18 (No.1) ◽  
pp. 96-107 ◽  
Author(s):  
Lam NGUYEN ◽  
Johannes BUHL ◽  
Markus BAMBACH
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Computer Aided Design ◽  
Tool Path ◽  
Heuristic Method ◽  
Support Material ◽  
Build Time ◽  
Cad Models ◽  
Aided Design ◽  
Wire Arc Additive Manufacturing

Three-axis machines are limited in the production of geometrical features in powder-bed additive manufacturing processes. In case of overhangs, support material has to be added due to the nature of the process, which causes some disadvantages. Robot-based wire-arc additive manufacturing (WAAM) is able to fabricate overhangs without adding support material. Hence, build time, waste of material, and post-processing might be reduced considerably. In order to make full use of multi-axis advantages, slicing strategies are needed. To this end, the CAD (computer-aided design) model of the part to be built is first partitioned into sub-parts, and for each sub-part, an individual build direction is identified. Path planning for these sub-parts by slicing then enables to produce the parts. This study presents a heuristic method to deal with the decomposition of CAD models and build direction identification for sub-entities. The geometric data of two adjacent slices are analyzed to construct centroidal axes. These centroidal axes are used to navigate the slicing and building processes. A case study and experiments are presented to exemplify the algorithm.

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