对CAD模型直接分层的方法研究

提出了直接对CAD实体模型进行分层处理以获取快速原型层片数据的方法,该方法无须进行从CAD到STL的数据转换,从而在根本上避免了由数据模型转换所引起的误差,且无需进行STL文件拓扑信息的提取及其错误的修复,极大地提高了快速原型的精度。     

Adaptive direct slicing of a commercial CAD model for use in rapid prototyping

Slicing a 3D graphic model into layers of 2D contour plots is an essential step for all rapid prototyping (RP) machines. Various methods are available, such as stereo lithography (STL) file slicing, direct slicing and adaptive direct slicing. Amongst these, adaptive direct slicing is the most advanced for its capability of adapting the slicing thickness according to the curvature of any contour. In this study, an adaptive direct slicing method complete with the algorithm for calculating the thickness of each layer is proposed. As an illustration of the method, the algorithm was programmed within the commercial CAD software package, PowerSHAPE. The method was shown to be fast and accurate in comparison with STL file slicing and direct slicing, which both used a constant layer thickness. An erratum to this article can be found at     

Adaptive direct slicing with non-uniform cusp heights for rapid prototyping

Adaptive slicing varies layer thickness by taking the geometry change of the CAD model in the build direction into account to improve surface finish. Direct slicing generates exact slice contours from the original CAD model and avoids an intermediate representation, known as an STL file. At present, most direct slicing approaches are restricted to some CSG solids or some CAD systems. In this paper, an approach toward adaptive direct slicing with non-uniform cusp heights independent of CAD systems for rapid prototyping is presented. First the geometry model is imported into the adaptive direct slicing system from CAD systems using the standard STEP format. Using OpenGL graphics libraries, the solid model is then displayed and the user is prompted to specify the allowable cusp height for each highlighted surface. Lastly, the CAD model is sliced adaptively with different cusp heights (tolerance requirements) for different surfaces. With non-uniform cusp heights, adaptive slicing has a higher efficiency. Implementation details and results are also presented.     

Multi-nozzle spraying path generation directly from scanned data for rapid prototyping

This study aims to build a triangular-mesh model directly from scanned 3D data points, which then generate the stereolithography (STL) file, thus avoiding the troublesome task of producing a CAD model. Accuracy of the triangular-mesh model is achieved because the pitch between data points is generally very small. In addition, the paper proposes a multi-nozzle path algorithm to increase both spraying efficiency and part accuracy. The processing procedure includes: (1) Establishing the triangular-mesh model from scanned data points, which are retrieved by means of contact- or non-contact type measuring machines as well as developing the algorithm to add the radius of the probe automatically. (2) Equally slicing the triangular-mesh solid model and plan spraying paths. (3) Determining the amount and diameter of nozzles appropriate for each slice to generate multi-nozzle spraying paths.     

A CAM-based path generation method for rapid prototyping applications

A wide range of rapid prototyping (RP) methods are available commercially. Even though the hardware and production materials of these RP methods differ, their production techniques are built on the same idea: layer-by-layer material additive manufacturing. Whatever the material is used, it is deposited, vulcanized, or melted by following a pre-determined path, and each layer is stowed on the previous one to create the 3D model which is designed by using a computer-aided design program. The path which is followed while creating the model is very crucial. In this paper, a novel idea for path generation for RP processes is introduced. This new method is based on computer numerical controlled milling operation. Although the RP process and the milling process are completely opposite of each other since one of them is an additive and the other one is a subtractive method, the paths which are followed for these operations are very similar and based on the same idea: The progress goes on layer by layer. In this novel method, cutter location source files are used to create paths for RP processes. Examples of the prototypes produced by using this new method are also presented in the paper.     

Adaptive slicing of functionally graded material objects for rapid prototyping

Slicing is a fundamental process planning task and an important procedure in rapid prototyping. However, most research currently focuses on the slicing of homogeneous objects and few approaches for slicing of heterogeneous objects have been reported in the literature. In this article, we present an approach for adaptive slicing of functionally graded material objects. Unlike homogeneous objects, functionally graded material objects contain both geometry and material information. The layer thickness is computed by considering not only geometry but also material variation along the build direction. The continuous material distribution in each layer is discretised into step-wise gradings by subdividing the slice into sub-regions, which can be regarded as homogeneous material regions. An algorithm that summarised the slicing procedure is described and an example is also presented.     

Direct slicing of cloud data with guaranteed topology for rapid prototyping

Direct slicing of point cloud is an effective way to integrate reverse engineering and rapid prototyping. However, since the input of the direct slicing process is discrete point data, connections between the points are absent. The lack of global structure may make the process fail to handle complex shapes that have multicontoured slices. Furthermore, it may cause accuracy loss at some important features, e.g., at topology transitions. In order to overcome the above limitations, this paper presents a method to extract topological structure from the point cloud and applies the structure into a moving-least square (MLS) surface-based direct slicing process. In addition to the topology extraction, two modifications are made to improve the efficiency and stability of the process: (1) a variation of the traditional projection-based MLS surface is adopted; (2) a rectification algorithm is presented in 2D contour generation to avoid biased curves when abrupt curvature changes happen. The improved direct slicing method is tested by some case studies including synthetic and scanned data. The efficacy of the algorithm is demonstrated by the results.     

快速成型技术中分层算法的研究与进展

根据对零件制造精度和效率的关注程度的不同,开发出了多种分层算法.在同等加工时间的情况下,根据加工精度的不同,将这些分层算法分为等层厚分层算法和适应性分层算法两类.通过对STL模型、原始CAD模型和点云数据的分析,讨论了两类分层算法的研究和发展,然后介绍了斜边分层算法和曲面分层算法等先进分层算法的原理和成果,最后讨论了快速成型分层算法的研究方向和趋势.     

Extraction of manufacturing information from design-by-feature solid model through feature recognition

Feature recognition is the key to the computer-aided design (CAD) and computer-aided manufacturing (CAM) integration to build a computer-integrated manufacturing system. There are two approaches to CAD feature recognition: platform-dependent and platform-independent. In the platform-independent approach, the part’s geometrical data are extracted from a neutral file such as DXF, IGES, or STEP. In contrast, the platform-dependent approach extracts the information of the design features directly from a design-by-feature solid model through the object-oriented model of a part. This paper explains a platform-dependent approach which is implemented to translate design features into manufacturing information. This approach begins with simplification using the suppression of fillets, and clustering non-intersecting design features is done. Then, the rule-based method is employed in order to recognize machining features. Finally, the needed manufacturing information such as tool accessing direction, dimensions, material removal regions, and geometrical and topological data is recognized. The application of the proposed system would be exhibited in generating machine path code for rapid prototyping and CNC machines and providing a database for computer-aided process planning. The proposed system was implemented on Autodesk Inventor and successfully tested for many complex 3D models.     

快速成型技术中分层算法的研究综述

作为快速成型技术中必不可少的环节,根据对零件制造精度和装配要求及效率的侧重不同,多年来多种分层算法已被国内外学者开发出来。在同等加工条件下,根据加工精度要求和层厚变化的不同,将分层算法大致分为等层厚分层算法和适应性分层算法两类。从常用的立体光刻(STL)模型、原始计算机辅助设计(CAD)模型和点云数据3种数据模型入手,简述了两类分层算法的研究和发展;介绍了采用斜边的分层算法、基于区域划分的混合算法、曲面分层算法等先进分层算法;讨论了分层算法中待解决的问题:直接分层算法的文件格式标准和轮廓的精确拟合等问题。最后,总结得出了分层算法未来的研究方向和趋势。     

Direct slicing and G-code contour for rapid prototyping machine of UV resin spray using PowerSOLUTION macro commands

Rapid prototyping processes produce parts layer by layer directly from 3D CAD models. An important technique is required to slice the geometric model of a part into layers and to generate a motion code of the cross-sectional contour. Several slicing methods are available, such as slicing from sterolithgraphy (STL) files, tolerate-error slicing, adaptive slicing, direct slicing, and, adaptive and direct slicing. This paper proposes direct slicing from 3D CAD models and generating a G-code contour of each layer using PowerSOLUTION software (Delcam International, Birmingham, UK). PowerSOLUTION includes two main modules: PowerSHAPE is used to build 3D CAD models and PowerMILL is used to produce G-Code tool paths. It provides macro language, picture files and cutting paths for secondary development work.The authors used macro commands to write an interface generating direct slicing from 3D CAD models and G-code contours for all layers. Most well-known controllers in the market accept the G-Code. Therefore, it is easier to apply this scheme in a CNC-machining center to produce rapid prototyping such as laminated object manufacturing (LOM) for complex geometries. The interface was successfully applied the interface to the UV resin spray rapid prototyping (UVRS-RP) machine that was developed to produce RP.     

Shape reconstruction, shape manipulation, and direct generation of input data from point clouds for rapid prototyping

Shape reconstruction from point clouds has received considerable attention in recent years on account of its ability to directly integrate reverse engineering with rapid prototyping. The primary objective of this study is to develop an integrated system that enables one to generate input data for rapid prototyping by constructing complete shape models from point clouds obtained with various measuring devices, including laser scanners, digitizers, and coordinate-measuring machines. We first present a novel approach to reconstructing a shape from point clouds based on implicit surface interpolation combined with domain decomposition. We then propose various related algorithms for generating input data for rapid prototyping, ranging from shape manipulation to complete solid generation. The validity of this new technique is demonstrated for a variety of point clouds with differing degrees of complexity.     

Nonplanar slicing and path generation methods for robotic additive manufacturing

Additive manufacturing (AM, generally called 3D printing) has attracted great research interests due to its ability to build complex shapes. It transforms design files to functional products through slicing and material accumulation. Typically, the planar slicing strategy is used in AM to convert CAD model into accumulating layers. However, when building overhang structures and curved parts, it often needs support structures and generates a large number of planar layers, which lead to the fact that it spends more time in manufacturing. To reduce the need for support structures and decrease the number of layers, this paper presents two nonplanar slicing approaches: a decomposition-based curved surface slicing strategy and a transformation-based cylinder surface slicing method. The former is implemented based on STEP models and the latter is capable of slicing mesh models. The feasibility of the proposed methods are validated by printing two parts with a robotic fused deposition modelling system.     

Determination of optimal build direction in rapid prototyping with variable slicing

Several important factors must be taken into consideration in order to maximize the efficiency of rapid prototyping (RP) processes. The ability to select the optimal orientation of the build direction is one of the most critical factors in using RP processes, since it affects part quality, build time, and part cost. This study aims to determine the optimal build-up direction when a part is built with the variable layer thickness for different RP systems. The average weighted surface roughness (AWSR) that is generated from the stair stepping effect, the build time, and the part cost using the variable layer thickness are all considered in the process. Using the multi-attribute decision-making method, the best orientation is determined among the orientation candidates chosen from the convex hull of a model. The validity of the algorithm is illustrated by an example. The algorithm can help RP users select the best build-up direction of the part and create an efficient process planning.     

Fast slicing orientation determining and optimizing algorithm for least volumetric error in rapid prototyping

Rapid prototyping fabricates physical prototypes from three-dimensional designing models using the additive process with layers. Aims at reducing the inevitable volumetric error induced in phrase of model slicing which impacts the shape accuracy of fabricated entity, a fast determining scheme of optimal slicing orientation for least volumetric error is proposed. The work analyses the staircase effect between two consecutive layers, then infers a direct computing formula of volume deviation of a whole model. Introduces the term of area weighted normal to express the significant effect of facet area on volumetric error and converts the optimal orientation determining problem to the least absolute deviation linear regression issue. Employs prominent components analysis on weighted normal set to obtain an approximate orientation efficiently, then optimizes the solution through few searchings in neighboring orientation space. The validity and efficiency of the algorithm are evaluated on several examples. Results demonstrate that proposed algorithm consumes less than 32 % of computation load and adaptively obtains the optimal slicing orientation.     

运用快速成型技术的人工骨骼实体模型重建

将快速成型技术运用于骨骼实体模型的三维重建研究中,以人体下肢股骨近端为例,通过对原始CT图像数据进行阈值分割,提取股骨近端轮廓曲线,拟合成数字模型.利用快速成型机可以将股骨近端的数字模型实体化,得到与实际骨骼拟合程度较高的实体模型.     

激光快速成形加工中扫描方式与成形精度的研究与实验

通过对激光快速成形加工中现有的激光扫描方式进行理论分析和实验验证，找出其生产零件翘曲以及引起其他误差的原因，提出一种扫描方法，解决由树脂收缩引起的零件翘曲和形状误差，并且省去光开关。     

EPS快速成型变向分区域扫描路径的研究

针对目前市场对聚苯乙烯泡沫塑料(EPS)三维切割加工的需要,基于现有的快速成形技术路径扫描策略的特点,结合EPS快速成形的特点,提出一种基于柱坐标的EPS变向分区域扫描路径加工算法,可以有效避免直接扫描方式所造成的过多重复切割。解决了现有EPS快速成型设备不能加工复杂三维模型的能力,实验测试证明,变向分区扫描方式生成的加工算法使得模型加工路径得到优化,提高了系统的加工效率并且减少了加工模型的表面粗糙度。     

Recommended slicing positions for adaptive direct slicing by image processing technique

Build time and accuracy are two contradicting issues that have been a major concern in rapid prototyping, and have led to the development of many slicing approaches including those applying adaptive slicing, direct slicing, and adaptive direct slicing concepts. Presented in this paper is an approach for adaptive direct slicing that applies image processing technique to determine appropriate thickness for each sliced layer and to recommend slicing positions on a 3D CAD model. Two orthogonal views of a model are captured and converted to be edge images before being analyzed, and based on the surface complexity on the two edge images, slicing positions are recommended. These positions are passed to the CAD software for slicing activities. This adaptive direct slicing approach has been implemented on LabVIEW platform and compared with uniform direct slicing approach and uniform cusp height approach. The results show that this slicing approach improved slicing performance by reducing the number of layer which has a direct impact on build time while maintaining surface quality at the same level as the thin uniform direct slicing. Since its inputs are the images of a CAD model instead of the model itself, this adaptive direct slicing supports any CAD software.     

基于RE/RP直接集成的医学模型快速原型开发

复杂曲面重构是反向工程的瓶颈,对于医学模型来说这一问题尤其突出,针对这一问题提出了一种基于CT图像的,以RE/RP直接集成技术为核心的医学模型的快速原型开发方法.在本方法中对扫描得到的CT切片数据直接进行切片处理,根据截面切点数据进行轮廓的识别与提取,获得实体的截面轮廓信息,输出STL格式文件给快速成型系统制造实体的物理原型件,从而避免曲面重构.