Machine path generation using direct slicing from design-by-feature solid model for rapid prototyping

Hayasi, Mohammad; Asiabanpour, Bahram

doi:10.1007/s00170-009-1944-8

Cited by 14 publications

(8 citation statements)

References 18 publications

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“…There are some approaches on extending TO algorithms for AM constraints, especially overhang (Garaigordobil et al 2018;Thore et al 2019), minimum length and overhang (Pellens et al 2019), support structure design within TO (Kuo et al 2018), build time reduction and support (Sabiston & Kim 2020) or overhang and support (Gaynor & Guest 2016). Concerning derivation of printing paths, many approaches focus on the production view (build time reduction, warpage minimization, support structure avoidance and similar; e.g., Yang et al 2003;Wang, Xi & Jin 2007;Hayasi & Asiabanpour 2009;Brown & de Beer 2013;Jin, He & Fu 2013;Alsoufi & El-Sayed 2017;Coupek et al 2018;Mi, Wu & Zeng 2018;Volpato & Zanotto 2019). However, there is a lack of infill patterns design for mechanical properties optimization.…”

Section: Motivation and Objectivementioning

confidence: 99%

Systematic development of load-path dependent FLM-FRP lightweight structures

Voelkl

Wartzack

2021

Des. Sci.

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Additive manufacturing offers a high degree of design freedom. When Design for Additive Manufacturing is conducted properly, lightweight potential can be exploited. This contribution introduces a novel design approach for the widespread fused layer modelling (FLM) technology when using orthotropic Fibre Reinforced Polymer filament. Its objective is to obtain stiff and strong load-path optimized FLM structures in a structured and algorithmic way. The approach therefore encompasses (1) build orientation optimization to consider weaker bonding between layers than intralayer; (2) topology optimization with orthotropic material properties to obtain favourable overall geometry and inner structure; (3) direct build path generation from optimized material orientation and alternatives to the direct generation and (4) simulation. The approach is demonstrated using a lift arm under multiple load cases and further demonstrator parts to show its general applicability. Lightweight potential of individual optimization steps and the influence of modifications contrasting general non-FLM-specific optimization are studied and discussed.

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Section: Motivation and Objectivementioning

confidence: 99%

Systematic development of load-path dependent FLM-FRP lightweight structures

Voelkl

Wartzack

2021

Des. Sci.

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“…For the CAD-dependent type, it relies on existing CAD software packages and their exposed application program interface (API) to perform the slicing process. Since 1990s, researchers have developed kinds of direct slicing (Cao and Miyamoto, 2003;Chang, 2004;Chen et al, 2001;Hayasia and Asiabanpourb, 2009;Jamieson and Hacker, 1995;Sun et al, 2006). Another type of direct slicing is independent of any existing CAD modeling package.…”

Section: Direct Slicingmentioning

confidence: 99%

A new two-step adaptive direct slicing approach for bio-scaffolds in tissue engineering

Liu

2017

RPJ

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Purpose This paper aims to propose the new two-step adaptive direct slicing method for building bio-scaffold with digital micro-mirror device (DMD)-based MPμSLA systems. Design/methodology/approach In this paper, the authors proposed a new approach to directly slice a scaffold’s CAD model (i.e the three-dimensional model built by computer-aided design platforms) and save the slices’ data as BMP (bitmap, i.e. the data format used in DMD) files instead of other types of two-dimensional patterns as an intermediary. The proposed two-step strategy in this paper, i.e. a CAD model’s exterior surface and internal architecture were sliced, respectively, at first, and then assembled together to obtain one intact slice. The assembly process is much easier and convenient based on the slice data in BMP format. To achieve the adaptive slicing for both the exterior part and internal part, two new indices, the exterior surface-dominated index and internal architecture-dominated index, are, respectively, utilized as the error estimation indices. The proposed approach in this paper is developed on SolidWorks platform, but it can also be implemented on other platforms. Findings The authors found that the approach is not only more accurate but also more efficient by avoiding the repeated running of those inefficient rasterization programs. The approach is able to save computer resource and time, and enhance the robustness of slicing program, as well as is appropriate for the scaffolds’ model with internal pore architecture and external free-form surface. Practical implications Bio-scaffolds in tissue engineering require precise control over material distribution, such as the porosity, connectivity, internal pore architecture and external free-form surface. The proposed two-step adaptive direct slicing approach is a good balance of slicing efficiency and accuracy and can be useful for slicing bio-scaffolds’ models. Originality/value This paper gives supports to build bio-scaffold with DMD-based MPμSLA systems.

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“…The resulting section at each Z level consists of curves such as lines, conic arcs, and Bezier spans. These entities that form a contour are then coded and saved into a custom, pre-defined file for generating a tool-path by using computer-aided manufacturing software presented by the same company, PowerSHARE [5].…”

Section: Related Workmentioning

confidence: 99%

“…This method demands a considerable amount of computer memory, and encounters difficulties in processing very large and complex STL files, thus affecting the final physical models' quality and build time. Hayasi and Asiabanpour [5] proposed a new tool-path generation algorithm that solves the computer bottleneck in tool-path generation for very large STL files. Tata et al [8] demonstrated that the productivity of the LM processes can be significantly improved by upgrading the slicing software.…”

Section: Related Workmentioning

confidence: 99%

Development of a Stereolithography (Stl) Input and Computer Numerical Control (Cnc) Output Algorithm for an Entry-Level 3-D Printer

Brown

Beer²,

Conradie

2014

The South African Journal of Industrial Engineering

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This paper presents a prototype Stereolithography (STL) file format slicing and tool-path generation algorithm, which serves as a data front-end for a Rapid Prototyping (RP) entrylevel three-dimensional (3-D) printer. Used mainly in Additive Manufacturing (AM), 3-D printers are devices that apply plastic, ceramic, and metal, layer by layer, in all three dimensions on a flat surface (X, Y, and Z axis). 3-D printers, unfortunately, cannot print an object without a special algorithm that is required to create the Computer Numerical Control (CNC) instructions for printing. An STL algorithm therefore forms a critical component for Layered Manufacturing (LM), also referred to as RP. The purpose of this study was to develop an algorithm that is capable of processing and slicing an STL file or multiple files, resulting in a tool-path, and finally compiling a CNC file for an entry-level 3-D printer. The prototype algorithm was implemented for an entry-level 3-D printer that utilises the Fused Deposition Modelling (FDM) process or Solid Freeform Fabrication (SFF) process; an AM technology. Following an experimental method, the full data flow path for the prototype algorithm was developed, starting with STL data files, and then processing the STL data file into a G-code file format by slicing the model and creating a tool-path. This layering method is used by most 3-D printers to turn a 2-D object into a 3-D object. The STL algorithm developed in this study presents innovative opportunities for LM, since it allows engineers and architects to transform their ideas easily into a solid model in a fast, simple, and cheap way. This is accomplished by allowing STL models to be sliced rapidly, effectively, and without error, and finally to be processed and prepared into a G-code print file. OPSOMMING'n Prototipe stereolitografie (STL) dokument ontvou en instrumenttrajek generasie algoritme vir 'n intreevlak driedimensionele drukker word in dié studie bekendgestel. Driedimensionele drukkers word hoofsaaklik in toevoegingsvervaardiging gebruik deur lae plastiek, keramiek of metaal in al drie rigtings (x, y en z) op 'n plat oppervlak te deponeer. Rekenaar numeriese beheer word egter benodig om die driedimensionele drukker te begelei. Die STL algoritme vorm dus 'n integrale deel vir laag-op-laag vervaardiging. Die doel van hierdie studie is om 'n algoritme te ontwikkel wat die vermoë het om een of meer STL dokumente te prosesseer en te ontvou en 'n gepaste instrumenttrajek te formuleer en daaruit beheerinstruksies vir die drukker te genereer. Die STL lêer is geprosesseer tot 'n Gkode lêer deur middel van die algoritme. Die ontwikkelde algoritme hou innoverende geleenthede in vir laag-op-laag vervaardiging, aangesien dit aan ingenieurs en argitekte toelaat om vinnig en maklik hul idees in driedimensionele soliede voorwerpe te omskep. Dit is moontlik deur die STL modelle vinnig en sonder foute te ontvou en te prosesseer tot 'n Gkode beheerlêer.

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Machine path generation using direct slicing from design-by-feature solid model for rapid prototyping

Cited by 14 publications

References 18 publications

Systematic development of load-path dependent FLM-FRP lightweight structures

Systematic development of load-path dependent FLM-FRP lightweight structures

A new two-step adaptive direct slicing approach for bio-scaffolds in tissue engineering

Development of a Stereolithography (Stl) Input and Computer Numerical Control (Cnc) Output Algorithm for an Entry-Level 3-D Printer

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