Adaptive tool-path generation of rapid prototyping for complex product models

Rapid prototyping (RP) provides an effective method for model verification and product development collaboration. A challenging research issue in RP is how to shorten the build time and improve the surface accuracy especially for complex product models. In this paper, systematic adaptive algorithms and strategies have been developed to address the challenge. A slicing algorithm has been first developed for directly slicing a Computer-Aided Design (CAD) model as a number of RP layers. Closed Non-Uniform Rational B-Spline (NURBS) curves have been introduced to represent the contours of the layers to maintain the surface accuracy of the CAD model. Based on it, a mixed and adaptive tool-path generation algorithm, which is aimed to optimize both the surface quality and fabrication efficiency in RP, has been then developed. The algorithm can generate contour tool-paths for the boundary of each RP sliced layer to reduce the surface errors of the model, and zigzag tool-paths for the internal area of the layer to speed up fabrication. In addition, based on developed build time analysis mathematical models, adaptive strategies have been devised to generate variable speeds for contour tool-paths to address the geometric characteristics in each layer to reduce build time, and to identify the best slope degree of zigzag tool-paths to further minimize the build time. In the end, case studies of complex product models have been used to validate and showcase the performance of the developed algorithms in terms of processing effectiveness and surface accuracy.     

一种非均匀自适应分层方法

自适应分层考虑了CAD模型在零件制作方向上的曲率变化,采用变层厚分层以提高零件的表面精度,一般的自适应分层方法对整个零件采取相同的表面精度要求(尖顶高度)。然而在实际应用中,零件的某些重要表面要求光滑一些,而其余相对不太重要的表面可以粗糙一些,即零件的不同表面具有不同的表面精度要求。通过对零件的不同表面采用不同的尖顶高度误差,可以进一步提高自适应分层的效率和零件的表面质量。提出一种非均匀自适应分层方法,用户选择好零件的制作方向后对零件的不同表面输入不同的表面精度要求,然后系统自动进行非均匀自适应分层,分层结果以SLC文件格式输出并可以直接送到各种快速成型系统进行加工。最后给出了分层实例并对结果进行了分析。     

Tool profile and tool path calculation for free-form thick-layered fabrication

In several application fields, large sized, free-form objects of various soft materials are widely used. Available layered prototyping technologies cannot be applied for fabrication of these kinds of objects due to size limitations. The authors have developed a novel approach of layered manufacturing that is the most appropriate for physical concept modeling. This paper presents the algorithms for geometrically-based modeling of the profile curve of the flexible blade tool. It also describes the algorithm for direct slicing of the CAD model. The second part of the paper deals with the algorithms for slicing, tool positioning and tool path calculation. On the front surfaces of the layers G², quasi G¹ continuity can be implemented at the transition from one layer to another. In the circumferential direction G⁰ continuity exists.     

STL模型特征信息的自适应分层的研究

模型的分层是3D打印前处理的一个重要环节，针对目前分层算法效率低、不能有效保留模型细微特征的问题，提出了一种新的基于STL模型特征信息的思想。首先提取模型的特征边，对特征边内实体表面采用区域增长算法进行表面分割，然后对分割后的表面判断其类型，最后对于不同的表面类型采用不同的分层求交处理算法。利用VC++6.0平台和OpenGL显示技术，依据模型表面几何特征自适应地变动层厚，减小台阶效应，加快分层效率，同样能很好地保留模型局部特征，且该算法可以根据实际模型的成型方向，实现分层方向的改变，保证成型零件的精度。     

Minimizing staircase errors in the orthogonal layered manufacturing system

The factors that generally affect the slicing error in layered manufacturing (LM) processes are first analyzed, and issues pertaining to the current methods to deal with the slicing error are discussed in this paper. A method based on a recently developed and implemented orthogonal LM system to reduce the overall slicing error is presented. In this method, the flat region is separated from the stereolithography (STL) model and different processing methods are applied to the different areas in the part geometry. In addition, the mathematical model for calculating the slicing error is derived and an approach based on a genetic algorithm has been developed to optimize the build orientation in terms of minimizing the slicing error. Case studies are given to demonstrate the effectiveness and efficiency of the method. Note to Practitioner-The staircase effect has been the major concern for industry to widely adopt rapid prototyping technologies. It will not only worsen the surface quality but also create errors on the parts built. This paper introduces a novel approach to minimizing staircase errors based on a multidirectional deposition approach. A mathematical method combined with a generic algorithm is used to minimize the slicing errors. From the case study given, the approach has been proven to be effective in minimizing staircase errors and thus improving the rapid prototyping (RP) built part quality.     

基于CAD模型的直接快速成型软件

目前国内普遍使用的基于STL模型的快速成型软件在精确度和灵活性上都存在着很多缺陷，在一定程度上影响了快速成型技术在生产中所起的作用，以三维几何造型系统GEMS6．0为平台，实现了一个基于CAD模型的直接快速成型软件，可进行分层、填充、构造支撑体以及生成CLI文件等，针对其中的若干问题给出了相应的算法和应用实例。     

有效保留模型特征的自适应分层算法

针对3D打印中已有自适应分层算法不能有效保留模型特征的问题,提出了一种新的识别和保留模型特征的自适应分层算法。首先,扩展了模型特征的定义,引入了模型特征丢失和偏移的概念;然后,提出了一种特征识别的方法,其识别模型特征的关键在于利用了模型特征出现的地方必然伴随着模型表面复杂度或切片轮廓数的变化这一性质;最后,在已有自适应分层算法的基础上,通过在特征附近用最小的分层厚度处理模型来保留模型的特征。在自主开发的软件Slicer3DP上实现了均匀分层、自适应分层和所提的分层算法,对比发现所提算法能有效解决模型特征的丢失和偏移,兼顾了分层精度和效率。仿真表明该算法可以用于对模型精度要求较高的3D打印中。     

Modelling cloud data using an adaptive slicing approach

In reverse engineering, the conventional surface modelling from point cloud data is time-consuming and requires expert modelling skills. One of the innovative modelling methods is to directly slice the point cloud along a direction and generate a layer-based model, which can be used directly for fabrication using rapid prototyping (RP) techniques. However, the main challenge is that the thickness of each layer must be carefully controlled so that each layer will yield the same shape error, which is within the given tolerance bound. In this paper, an adaptive slicing method for modelling point cloud data is presented. It seeks to generate a direct RP model with minimum number of layers based on a given shape error. The method employs an iterative approach to find the maximum allowable thickness for each layer. Issues including multiple loop segmentation in layers, profile curve generation, and data filtering, are discussed. The efficacy of the algorithm is demonstrated by case studies.     

基于STL的高性能分层处理软件的研发

本文分析了影响分层处理效率的主要因素,提出了基于三角形面片特征的快速排序算法和快速分层算法,并在此基础上开发了基于STL模型的高性能分层处理软件。大量实际应用结果表明,该软件高效、稳定、可靠。     

基于分层切片原理的三维雕刻算法

分析了多种基于STL模型的快速分层算法。在综合多种算法优点的基础上,首先提出了对三角面片的顶点按其切片方向进行从小到大排序,以快速滤除冗余顶点;并在此基础上建立三角面片的顶点链表及面向量,以实现STL模型的拓扑信息重构;最后基于所重构的拓扑信息,结合几何连续性分层算法实现高效的自适应分层算法。并通过C+〖KG-*3〗+实现了这一算法,证明了快速成型技术的分层制造思想可应用于三维雕刻的CAD/CAM,在技术上是可行的。     

Hollowing objects with uniform wall thickness

In rapid prototyping, we can significantly reduce the building time and expensive RP material consumption by building a hollowed prototype instead of a solid model. Presented in the paper is a new method to hollow out solid objects with uniform wall thickness to speed up the part building processes in rapid prototyping systems. To achieve uniform wall thickness, it is necessary to generate internal contours by slicing the offset model of an STL model. Since computing an offset model of an STL model involves many difficulties, this paper proposes a new algorithm that computes internal contours without computing the offset model. The proposed algorithm is efficient and relatively easy to implement, because it employs well-known 2D geometric algorithms, such as planar curve offsetting and tracing innermost curves. Various examples have been tested with implementation of the algorithm, and some examples are presented for illustration.     

Interfacing geometric model data with rapid prototyping systems

The direct slicing of CAD models created in CADDS V to generate geometric data for rapid prototyping using fused feposition modeling technique (FDM) is presented in this paper. The report file from an explicit model is accessed for obtaining model data. Algorithms have been developed for determining the volumes of model material as well as support materials. New algorithms have been developed for filling the sheet solid. A simulation module has been developed to verify whether the filling is correctly done. Example of a model is manufactured using this approach is also presented in this paper.     

Efficient slicing procedure based on adaptive layer depth normal image

In layered modeling for rapid prototyping of products, compromising slicing accuracy and time is a critical issue. Based on adaptive Layer Depth Normal Image (LDNI), this paper proposes an efficient algorithm to achieve this compromise for complex Constructive Solid Geometry (CSG) models. First, each primitive at the tree leaf is converted into an adaptive LDNI solid whose Boolean operation can be performed efficiently. Then, a layered model is constructed directly from the Booleaned LDNI solid since it is actually a set of a layered and ordered point cloud. In addition to speed, efficient use of memory is also taken into account in design of the LDNI-based slicing algorithm. The capability and efficiency of this slicing algorithm are demonstrated by examples.     

基于压缩体素模型的快速成型直接切片算法*

基于STL文件模型的间接分层切片算法存在缺乏拓扑信息, 面误差诊断修复困难等问题,结合压缩表示形式的体素模型特点,提出了一种新的基于压缩体素模型直接切片分层优化算法.该算法利用Dexel模型记录的Dexel射线和物体交点所表达的物体表面点位置,通过设定分层平面厚度等参数获得截面轮廓数据,生成可直接适用于快速成型系统的共用层接口CLI文件.该算法在虚拟油泥造型系统中得到了应用,实验结果表明算法稳定、分层效果良好.     

Process planning strategies for solid freeform fabrication of metal parts

Process planning of additive manufacturing of metals is a research interest because of the applications of solid freeform fabrication of metal parts in industry. The strategy is to transform the model of the part into the combinations of 2D layers that will be deposited using different fabrication methods. Process planning for metal deposition in this paper consists of three major modules: spatial decomposition, slicing of the part, and toolpath generation for every slicing layer. Algorithmic improvements are proposed and implemented for these major modules. For spatial decomposition, 3D part decomposition based on modular boundary models and centroidal axis extraction methods are combined to decompose parts more robustly and reliably. For generating slicing layers, a planning process for building non-uniform layers is investigated to greatly increase the variety of the parts that can be manufactured without the need of support structure. For toolpath generation methods, optimization of the generated toolpath is studied especially for complex thin-wall structures to ensure the deposition quality. Experiments were carried out to evaluate the improvements of the major modules of process planning strategies for rapid manufacturing.     

Feature-based reverse modeling strategies

We presented two integrated solution schemes, sectional feature based strategy and surface feature based strategy, for modeling industrial components from point cloud to surfaces without using triangulation. For the sectional feature based strategy, slicing, curve feature recognition and constrained fitting are introduced. This strategy emphasizes the advanced feature architecture patterns from 2D to 3D in reverse engineering. The surface feature based strategy relies on differential geometric attributes estimation and diverse feature extraction techniques. The methods and algorithms such as attributes estimation based on 4D Shepard surface, symmetry plane extraction, quadric surface recognition and optimization, extruded and rotational surface extraction, and blend feature extraction with probability and statistic theory are proposed. The reliable three-dimensional feature fabricated the valid substratum of B-rep model faultlessly. All the algorithms are implemented in RE-SOFT, a reverse engineering software developed by Zhejiang University. The proposed strategies can be used to capture the original design intention accurately and to complete the reverse modeling process conveniently. Typical industrial components are used to illustrate the validation of our feature-based strategies.     

基于特征选择的VNF资源需求预测方法

针对在网络切片场景下以往的VNF(虚拟网络功能)资源分配策略无法满足动态的资源需求,很容易导致资源分配不足或过度分配的问题,提出了一种基于两阶段算法(two-stage algorithm,TSA)的VNF资源需求预测方法.该方法首先基于数据特征筛选出与预测目标高度相关的候选特征集,然后利用贪婪式前向搜索策略对候选特征集进一步筛选获得最优特征集,最终训练出不同类型的预测模型.仿真结果表明,基于该方法所训练的模型可以获得更好的预测性能,同时该方法的可扩展性较好,训练好的模型可以直接集成到现有的VNF部署算法中应用.     

Automatic multi-direction slicing algorithms for wire based additive manufacturing

One of the key challenges in Additive Manufacturing is to develop a robust algorithm to slice CAD models into a set of layers which requires minimal support structures. This paper reports the concept and implementation of a new strategy for multi-direction slicing of CAD models represented in STL format. Differing from the existing multi-direction slicing approaches that are mainly focused on finding an optimal volume decomposition strategy, this study presents a decomposition-regrouping method. The CAD model is firstly decomposed into sub-volumes using a simple curvature-based volume decomposition method. Then a depth-tree structure based on topology information is introduced to merge them into ordered groups for slicing. In addition, a model simplification step is introduced before CAD model decomposition to significantly enhance the capability of the proposed multi-direction strategy. The proposed strategy is shown to be simple and efficient on various tests parts especially for geometries with large number of holes.     

过程模型切片技术的研究

将程序切片技术引入到过程模型中,定义过程模型中的关联关系和数据连接关系,在此基础上给出了过程模型的切片定义,并定义了过程模型的三种切片：前向切片,后向切片和双向切片,提出了前向切片、后向切片和双向切片的算法,最后通过实例分析证明了该算法的可行性和实用性。     

基于医学图像序列面绘制的骨组织快速成型方法

针对人工骨组织快速成型中轮廓线轨迹生成复杂、分层效率低的问题,提出了一种简化三角片模型分层过程的方法。应用移动立方块（MC）算法对医学图像序列进行面绘制重建,根据重建过程的顺序对三角片集合分组,然后采用对边追踪的方法计算切平面与其对应三角片数组的交点轮廓线数据。简化后的分层效率相对于三角网格文件（STL）模型分层平均提高了4.65%。实验结果表明,所提方法可以直接从人体骨组织医学图像序列生成可供3D打印的轮廓线数据,从而实现骨组织的快速成型。