The development of a CAD environment to determine the preferred build-up direction for layered manufacturing

Stereolithography is a process used to produce polymer components rapidly directly from a computer representation of the part. There are several factors to be considered in order to make efficient use of the process. In particular, the build-up orientation of the part critically affects the part accuracy, the total build time and the volume of the support structures. The purpose of this study is to determine the optimal build-up part orientation for the StereoLithography Apparatus (SLA) process to improve part accuracy, and minimise the total build time and the volume of the support structure. Additionally, an algorithm is developed to calculate the staircase area, quantifying the process errors by the volume of materials supposed to be removed or added to the part, and the optimal layer thickness for the SLA system which can handle the variable layer thickness. Thus, the optimal part orientation is determined based on the user's selections of primary criteria and the optimal thickness of layers is calculated for any part orientation.     

A decision support system for the selection of a rapid prototyping process using the modified TOPSIS method

As a new technology that fabricates a three-dimensional (3D) physical model from computer-aided design (CAD) data using an additive process, rapid prototyping (RP) has been developed to reduce product development time and cost. Recently, many newly emerging techniques of RP have been commercialized worldwide. This paper deals with the selection of an optimal RP system that best suits the end use of a part by using multiple-attribute decision making and the test part designed with conjoint analysis to reflect users’ preference. Evaluation factors include only the major attributes that significantly affect the performance of an RP system such as accuracy, roughness, strength, elongation, part cost and build time. Crisp values such as accuracy and surface roughness are obtained with a new test part developed in this study. The part cost and build time are identified as falling within approximate ranges due to varying costs and many variable parameters. They are presented as linguistic values that can be described with triangular fuzzy numbers. Based on the evaluation values obtained, an appropriate RP process for a specific part application can be selected using a modified technique of order preference by a similarity to ideal solution (TOPIS) method given crisp data and linguistic variables as the alternatives of attributes. Finally, each attribute’s weight is assigned using a pairwise comparison matrix. Determined using these weights, the final ranking order aids in the selection of the RP system.     

A unit sphere discretization and search approach to optimize building direction with minimized volumetric error for rapid prototyping

As a material-additive process, rapid prototyping (RP) has shown its capability in creating complex geometries that traditional material-removal processes cannot accomplish. However, its layer manufacturing nature still subjects itself to undesired staircase effects. It has been shown that staircase effects have relationship with the building orientation in RP processes. In order to minimize staircase effects, the building orientation has to be properly selected prior to the implementation of RP processes. This paper presents a method to select the optimal building direction in RP processes that leads to the minimized volumetric error. In order to explore the global directional space, a unit sphere is uniformly discretized first to represent the potential directions in a 3-dimensional (3-D) space. Following that, each facet comprising the STL geometric model is mapped onto the discretized unit sphere as a great circle individually, which represents the optimal directions for that facet. In order to find the globally optimal solution, both an exhaustive search and a genetic algorithm (GA)-based searching strategy are presented to identify the globally optimal direction for building the 3-D geometry. At the end of the paper, examples are presented to show the effectiveness of the method.     

Decision support tool for selecting fabrication parameters in stereolithography

The selection of fabrication (build) parameters is the most important task performed by the operator of a layer manufacturing (LM) system. In order to select the best parameter configuration for a part, the operator should be able to compare different alternatives and evaluate them under specific constraints, in terms of fabrication cost and quality. In the present paper, a software decision support tool for build parameters selection in stereolithography is presented. Build orientation and layer thickness are proposed as the primary parameters for the definition of candidate solutions, which are evaluated according to a weighted multi-criteria objective function. As the objective function criteria, the build time, surface roughness and process error are employed. The criteria estimation is based on experimentally derived analytical equations or computed from the STL representation of the part. To further enhance the evaluation process, the software tool exports VRML models that incorporate surface roughness or stairstepping data through colour codification. An erratum to this article can be found at     

Electron beam melting of gamma titanium aluminide and investigating the effect of EBM layer orientation on milling performance

Electron beam melting (EBM) is one of the growing processes of additive manufacturing technology (AMT) to fabricate 3D parts from various difficult-to-process materials such as titanium alloys. A major limitation of the EBM process is the poor surface finish of the produced parts which ultimately demands a subsequent subtractive method (secondary finishing operation) to improve the surface finish for shaping the part to be fit for-end use applications where high surface finish is commonly required. With respect to the EBM layer build direction, the fabricated part has different orientations with varying surface characteristics. Therefore, in order to perform secondary finishing operation (e.g., milling) there are different choices of EBM part orientation to select the direction of tool feed. In this research, 3D parts of titanium alloy (gamma titanium aluminide; γ-TiAl) are additively manufactured through EBM process. The effect of EBM layer/part orientation on the milling performance is further investigated in terms of surface finish improvement and edge chipping evaluation. It has been observed that the EBM layer/part orientation with respect to milling tool feed direction (TFD) plays a vital role in milling performance. Thus, a care must be taken to select the appropriate tool feed direction and layer/part orientation in order to achieve maximum surface finish with minimum edge chipping. The results revealed the vertical milling can be adopted as a secondary finishing operation to be performed on EBM produced parts of γ-TiAl and it allows to significantly improve the poor surface finish generated by EBM (R_a 31 μm). Furthermore, among the available part orientation choices, the part orientation in which the milling tool is fed across the EBM layer build direction is the best orientation resulting into high surface finish (R_a 0.12 μm) with relatively smooth edges (minimum chipping-off).     

RP part surface quality versus build orientation: when the layers are getting thinner

Surface quality is a very important factor to be considered in determining part build orientation in rapid prototyping (RP) processes. Previous research has shown that parts built with inclined planes or curved surfaces along the build orientation have large staircase effect, thus have higher surface roughness compared to parts built with only vertical surfaces. However, as layers are getting thinner in rapid prototyping processes, the opposite might be true. In this study, a number of experiments and measurements are conducted first. In a single machine setup, two cylinders are built, one along axial direction and the other along transverse direction using an Objet® machine. Measurements have shown that surface roughness of RP parts built along the transverse direction is better than those from the axial direction. Through analysis and observation, the authors can conclude that when layers are small enough, surface curvature or slope along the build orientation may no longer be a major concern for RP part surface quality. Instead, the authors have observed that on-the-layer contour layout may cause even more serious surface quality problem. In other words, surface quality is not only dependent on build orientation, but more on scanning orientation on layers.     

Part Orientation in Stereolithography

Rapid prototyping (RP) machines reduce the lead time and cost of new products by automating the prototype manufacturing phase of the product development process. However, it is necessary for operators to orientate the prototype correctly in the RP machine to obtain the best trade-off between time, cost, and accuracy. The purpose of this work is to produce a decision-support tool to help RP users in this task. The tool is aimed at stereolithography which is the most widely adopted RP technology. The tool is a feature-based system produced using an object-orientated programming language and a solid modelling CAD environment. Cost, time, problematic features, optimally orientated features, overhanging area, and support volume are considered when recommending a build direction to the user. Three sample parts were used to illustrate the performance of the system. The system yielded the best surface finish and correctly highlighted several problem features.     

Efficient calculation of trapped volumes in the layered manufacturing process

Prototypes of a design are always needed for the purposes of visualisation and evaluation for manufacturability, functionality, and aesthetic appearance. Since the prototyping process requires a significant amount of cost and time, various rapid prototyping processes have recently been introduced. However, it is usually necessary for a part built up by a rapid prototyping system to be finished by a post-processing process, in which the stair steps on the surfaces, the support structures (if they exist), and the unprocessed material are eliminated. This post-processing is usually done manually and is a time-consuming task. Eliminating the trapped volumes (the volume of the unprocessed material entrapped by the solidified portion) is sometimes impossible in some processes.This study provides a designer with a tool to detect the existence of trapped volumes and to calculate the quantity in a given build-up direction, so that a suitable build-up direction is chosen or the part is built in pieces to avoid the problems caused by the trapped volumes. Since the proposed algorithm can efficiently calculate the amount of the trapped volumes in any build-up direction, it has the potential for such applications as optimising the build-up direction to minimise the trapped volumes.     

A Generic Part Orientation System Based on Volumetric Error in Rapid Prototyping

The paper presents the development of a generic part orientation system for rapid prototyping by considering the issue of volumetric error encountered in parts during the layer by layer building process in a rapid prototyping (RP) system. An algorithm is developed that slices the part with horizontal planes and computes the volumetric error in the part at different orientations by rotation about user-specified axes. The system recommends the best orientation based on the least amount of volumetric error in the part. The system has been tested using several examples of simple and complex parts. The generic part orientation system is believed to be first of its kind based on a volumetric error approach and will be useful for RP users in creating RP parts with a higher level of accuracy and surface finish, and also for intelligent process planning in rapid prototyping. RID=" ID=" <E5>Correspondence and offprint requests to</E5>: Assoc. Prof. S. H. Masood, CAD/CAM/CAE Group, Industrial Research Institute Swinburne, Swinburne University of Technology, Hawthorn, Melbourne, 3122 Australia. E-mail: smasood&commat;swin.edu.au     

快速成型制作的时间分析及多零件制作的组合布局优化研究

由于快速成型系统的运行成本很高,需要研究缩短零件的制作时间和减小制作成本的方法。基于SOUP600GH光固化成型机,介绍了零件具体的制作过程和制作时间组成,分析了零件制作方向、分层厚度以及激光扫描速度等因素对优化制作效率的影响。通过10组多零件制作实验,对每组单个零件的平均制作时间进行分析对比,指出了多个零件同时制作对提高制作效率的显著作用,进而主要从减少辅助制作时间的角度研究了多零件制作组合布局优化的准则和方法,并用矩形包络简化布置的方法建立了二维布局优化的数学模型。研究表明,多零件制作及其组合布局优化对提高快速成型的制作效率和降低制作成本都具有重要意义。     

Optimizing process parameters for selective laser sintering based on neural network and genetic algorithm

Selective laser sintering (SLS) is an attractive rapid prototyping (RP) technology capable of manufacturing parts from a variety of materials. However, the wider application of SLS has been limited, due to their accuracy. This paper presents an optimal method to determine the best processing parameter for SLS by minimizing the shrinkage. According to the nonlinear and multitudinous processing parameter feature of SLS, the theory and the algorithms of the neural network are applied for studying SLS process parameters. The process is modeled and described by neural network based on experiment. Moreover, the optimum process parameters, such as layer thickness, hatch spacing, laser power, scanning speed, work surroundings temperature, interval time, and scanning mode are obtained by adopting the genetic algorithm based on the neural network model. The optimum process parameters will be benefit for RP users in creating RP parts with a higher level of accuracy.     

Part orientation optimisation for the additive layer manufacture of metal components

In a number of additive layer manufacturing processes, particularly for metals, additional support structure is required during the build process to act as scaffolding for overhanging features and to dissipate process heat. Such structures use valuable raw materials and their removal adds to post processing time. The objective of this study was to investigate whether a simple, single objective optimisation technique could be used to find the best orientation of the part, that would minimise the volume of support needed during the build. Not only reducing waste but potentially providing an effective and consistent approach for inexperienced users to orient components during manufacture. Software was developed using MatLab with an unconstrained optimisation algorithm implemented to search the different rotations of the part and identify the configuration with the least requirement for support volume. The algorithm was gradient based, and so multiple starting points were used to identify a global minimum. The efficacy of the algorithm is illustrated with three different case studies of increasing complexity. Additionally, the component of the final study was manufactured, which allowed a comparison between the algorithm’s results and the orientations chosen by experienced operatives. In two of the three case studies, the software was able to find good solutions for the support volume minimisation. For the manufactured part, only one of the results matched the orientation chosen by the operators, the other was orientated in a similar way but the difference added significantly to the required support volume. Future developments of the software would benefit from incorporating the expertise of the manufacturing operative.     

Effect of delay time on part strength in selective laser sintering

Selective laser sintering (SLS) is one of the most popular layered manufacturing processes used for making functional prototypes of polymers and metals. It is a powder-based process in which layers of powder are spread and laser is used to sinter selected areas of preheated powder. In the present work, experimental investigations have been made to understand effect of delay time on SLS prototypes. Delay time is the time difference for laser exposure between any two adjacent points on successive scanning lines on a layer. Tensile specimens of polyamide material as per the ASTM standard are fabricated on SLS machine keeping delay time range constant for the entire specimen. Specimens are fabricated for different ranges of delay time and tested on universal testing machine for tensile strength. An optimum value of delay time range is obtained experimentally. As delay time depends on part build orientation, an algorithm has been developed and implemented to find out optimum part build orientation for improving tensile strength. The obtained results from developed code are validated experimentally for tensile specimen. Case study for a typical 3D part is also presented to demonstrate the capabilities of developed algorithm.     

Optimization of stereolithography process parameters for part strength using design of experiments

Rapid prototyping (RP) is an emerging technology that has been implemented in many spheres of industry – particularly in the area of new product development. Growth of this field has been rapid in recent years. Stereolithography (SL) is one of the most popular RP process used for rapid tooling applications. There are several process parameters contributing to the strength of an SL product. The contribution of three parameters; namely, layer thickness, post curing time and orientation are most significant. In light of this concern, an attempt has been made to study and optimize these process parameters for maximum part strength, and develop an empirical relationship between process parameters and part strength through design of experiments (DOE). The proposed DOE is verified with the data of experiments conducted under standard conditions.     

Cutting path generation of linear hotwire cutter for VLM-ST

Most rapid prototyping (RP) processes adopt a solid CAD model, which will be sliced into thin layers of constant thickness in the building direction. Each cross-sectional layer is successively deposited and, simultaneously, bonded onto the previous layer; eventually, the stacked layers form a physical part of the model. A new thick-layered RP process, the transfer-type variable lamination manufacturing process using expandable polystyrene foam sheets (VLM-ST), has been developed to reduce building time by employing thick layers and to improve the surface finish of parts with a sloping surface. This paper describes the method to generate the unit shape layer (USL), the cutting path data of the four-axis hotwire cutter for the VLM-ST process. The USL is the basic unit of cutting and building in the VLM-ST process and it is also the basic unit of cutting path data of each layer. The USL includes data such as layer thickness, positional coordinates, side angles of each layer, and reference shape. The method to generate the USL is as follows: (1) the mid-slice of each layer is generated from the CAD model, (2) each mid-slice is converted into a simply-connected domain, (3) the rotation angle of the hotwire of the cutting system is calculated for each layer, and (4) the reference shape of each layer is generated for manual stacking. The procedure to generate the cutting path data of the linear hotwire cutter for VLM-ST was practically applied and verified for various three-dimensional shapes.     

Build orientation determination of multi-feature mechanical parts in selective laser melting via multi-objective decision making

Selective laser melting (SLM) is a unique additive manufacturing (AM) category that can be used to manufacture mechanical parts. It has been widely used in aerospace and automotive using metal or alloy powder. The build orientation is crucial in AM because it affects the as-built part, including its part accuracy, surface roughness, support structure, and build time and cost. A mechanical part is usually composed of multiple surface features. The surface features carry the production and design knowledge, which can be utilized in SLM fabrication. This study proposes a method to determine the build orientation of multi-feature mechanical parts (MFMPs) in SLM. First, the surface features of an MFMP are recognized and grouped for formulating the particular optimization objectives. Second, the estimation models of involved optimization objectives are established, and a set of alternative build orientations (ABOs) is further obtained by many-objective optimization. Lastly, a multi-objective decision making method integrated by the technique for order of preference by similarity to the ideal solution and cosine similarity measure is presented to select an optimal build orientation from those ABOs. The weights of the feature groups and considered objectives are achieved by a fuzzy analytical hierarchy process. Two case studies are reported to validate the proposed method with numerical results, and the effectiveness comparison is presented. Physical manufacturing is conducted to prove the performance of the proposed method. The measured average sampling surface roughness of the most crucial feature of the bracket in the original orientation and the orientations obtained by the weighted sum model and the proposed method are 15.82, 10.84, and 10.62 μm, respectively. The numerical and physical validation results demonstrate that the proposed method is desirable to determine the build orientations of MFMPs with competitive results in SLM.     

PART BUILDING ORIENTATION OPTIMIZATION METHOD IN STEREOLITHOGRAPHY

Aiming at the part quality and building time problems in stereolithography (SL) caused by unreasonable building orientation, a part building orientation decision method in SL rapid prototyping (RP) is carried out. Bringing into fall consideration of the deformation, stair-stepping effect, overcure effect and building time related to the part fabrication orientation, and using evaluation function method, a multi-objective optimization model for the building orientation is defined. According to the difference in the angles between normal vectors of triangular facets in standard triangulation language (STL) model and z axis, the expressions of deformation area, stair-stepping area, overcure area are established. According to the characteristics in SL process, part building time is divided into four sections, that is, hatching scanning time, outline scanning time, support building time and layer waiting time. Expressions of each building time section are given. Considering the features of this optimization model, genetic algorithm (GA) is used to derive the optimization objective, related software is developed and optimization results are tested through experiments. Application shows that this method can effectively solve the quality and efficiency troubles caused by unreasonable part building orientation, an automatic orientation-determining program is developed and verified through test.     

DIRECT AND ADAPTIVE SLICING ON CAD MODEL OF IDEAL FUNCTIONAL MATERIAL COMPONENTS （IFMC）

A brand new direct and adaptive slicing approach is proposed, which can apparently improve the part accuracy and reduce the building time. At least two stages are included in this operation: getting the crossing contour of the cutting plane with the solid part and determining the layer thickness. Apart from usual SPI algorithm, slicing of the solid model has its special requirements. Enabling the contour line segments of the cross-section as long as possible is one of them, which is for improving manufacturing efficiency and is reached by adaptively adjusting the step direction and the step size at every crossing point to obtain optimized secant height. The layer thickness determination can be divided into two phases: the geometry-based thickness estimation and the material-based thickness verifying. During the former phase, the geometry tolerance is divided into two parts: a variety of curves are approximated by a circular arc, which introduces the first part, and the deviation error between the contour     

An optimal placement of CLD treatment for vibration suppression of plates

A study on optimal placement of constrained-layer damping (CLD) treatment for vibration suppression of plates is presented. A mathematical model is derived using the energy approach. This model allows both the constraining layer (CL) and the viscoelastic layer (VEM) to be either as thick as the host or very thin. The influence of treatment thickness on damping effects is particularly addressed. From the simulated results, it is found that the best damping performance occurs as the CL thickness is twice that of the VEM thickness. As to the optimization process, an objective function including structural damping ratios, resonant frequencies’ shift, and CLD thickness is defined. In optimization, the structural damping plays the main performance index and the frequencies’ shift and CLD thickness play as penalty functions. A topographical method in conjunction with the complex method is used to search for the global minimum. Examples are illustrated and the effects of weighting factors are discussed. Individual effects of weighting factors can be useful for designers, since the designers can build up a better sense of how CLD treatment improves the vibration suppression.     

Influence of process parameters on part quality and mechanical properties for DMLS and SLM with iron-based materials

Rapid manufacturing is an advanced manufacturing technology based on layer-by-layer manufacturing to produce a part. This paper presents experimental work carried out to investigate the effects of scan speed, layer thickness, and building direction on the following part features: dimensional error, surface roughness, and mechanical properties for DMLS with DS H20 powder and SLM with CL 20 powder (1.4404/AISI 316L). Findings were evaluated using ANOVA analysis. According to the experimental results, build direction has a significant effect on part quality, in terms of dimensional error and surface roughness. For the SLM process, the build direction has no influence on mechanical properties. Results of this research support industry estimating part quality and mechanical properties before the production of parts with additive manufacturing, using iron-based powders.