基于STL模型的轮廓线自适应分层方法研究

目前,大多数快速成型系统在表达CAD模型时仍采用STL模型。由于快速成型自身的特点,对STL模型进行分层处理是其必由之路。在分析了传统的STL模型分层方法的基础上,提出了一种基于STL模型的轮廓外形线自适应分层的方法,然后通过实例对该自适应分层方法进行了验证,证明了该方法的可行性和正确性。     

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。     

三维实体零件分层处理软件的研究与开发

STL作为CAD与RP系统之间数据接口的事实标准，所有的RP系统都支持该数据接口。分层处理是目前快速成形制造的首要环节。该分层软件采用STL模型整体拓扑信息的分层处理思想，分层处理效率高。分析了分层处理软件的总体结构和各模块的功能，给出其流程图，最后，为三维实体零件在计算机坐标系和在快速制模设备坐标系中的坐标转换问题，提出新的解决方案。     

NURBS曲线在快速原型制造系统中的应用

大多数快速原型制造系统采用 STL 文件作为与 CAD系统之间的数据交换接口。但是 ,STL 文件是通过用一系列的三角片逼近实际零件表面而产生的 ,STL 文件本身及其创建过程均存在许多问题。要提高模型的精度 ,就必须增加三角片的数量 ,同时减小三角片的尺寸。这必然造成 STL 文件庞大 ,后续处理时间较长 ,而且易产生缺陷 ,使后续处理不能进行。针对上述问题 ,本文分析了 STL文件的不足 ,提出一种 CAD系统与 RPM系统之间新的数据交换方法。该方法对 CAD系统中的真实模型直接切片 ,将切片后所得到的轮廓数据作为 CAD系统与快速原型制造系统之间的数据交换接口。该切片算法已在“超人 2 0 0 0 CAD/ CAM”系统中实现 ,算法表现稳定     

STL模型切片数据的优化技术研究

快速成型技术是一种基于离散/堆积成型原理的制造方法,它是在计算机的控制与管理下,根据零件的CAD模型,采用材料精确堆积的方法制造原型或零件的.目前在快速成型技术中,由于成型机的数据接口问题,通常在切片之前需要将CAD模型转换成STL模型,而STL模型的某些区域存在冗余的三角形,这些三角形的存在增加了切片时候的求交运算量.通过剔除部分狭长的钝角三角形,实现了对STL模型的合理优化,节省了文件存储空间和后续数据处理时间,具有一定的工程意义.     

光固化成型技术的实体表面防变形方法研究

提出采用对三维模型抽壳的方法来达到模型内部中空的目的。其中空部分由支撑材料石蜡(VisiJet S300)进行填充,通过增加支撑材料密度来减小打印实体变形;同时,由于模型内部中空,与未抽壳的打印模型相比,在STL文件分层数相同的情形下,其分层面接触面积远远小于未抽壳模型,层间应力极小,从而有效防止变形;另一方面,模型固化及二次固化中易发生的线性收缩在抽壳实体中未对变形有显著地影响。文中对该方法进行了实验验证、对比分析,结果表明该方式可有效降低打印实体变形。     

带有装配定位系统的STL模型直接生成算法研究

提出了在分割STL模型上直接添加装配定位系统的方法。分析了分割后各子零件STL文件中三角面片的特点,建立了有效的带有装配定位系统的STL模型直接生成算法,保证了完整原型的尺寸和形状精度。     

异质材料零件的集成设计与制造研究

异质材料零件的CAD与CAM研究的相互孤立使其难以形成有效的设计与制造体系。文中提出并研究了一种基于STL数据格式的异质材料零件设计与制造一体化方法。以异质材料零件的逐层分解、网格细化及均匀化为基础,逐步对微四面体空间单元网格节点、表面及其内部进行结构与材料的并行设计,之后对异质材料零件CAD模型进行切片分层,获得含有结构信息和色彩信息的系列彩色切片数据,并采用基于数字化微滴喷射技术的快速成型工艺较为系统地实现了异质材料零件的原型设计与制造。     

基于STL数据的快速原型分割制作算法研究

针对快速原型尺寸超过成型机成型空间尺寸这一实际制造问题，提出了一种大型快速原型分割制作方法。根据STL文件的特点，建立了一个有效的截面三角剖分算法。分析了分割后各部分子零件中三角面片的特点，提出并实现了子零件STL文件生成算法。扩大了快速原型的应用范围，提高了制造效率。     

一种基于STEP的CAD模型直接分层方法

提出了一种基于产品模型数据交换标准的3维计算机辅助设计实体模型直接分层方法,零件的原始计算机辅助设计模型以产品模型数据交换标准中性文件的格式输入分层系统,系统提取其几何拓扑信息并重建计算机内部几何模型。用户选择零件的制作方向并指定分层厚度后,系统自动对计算机辅助设计模型进行直接分层,分层结果可直接送到各种快速成型系统加工。基于产品模型数据交换标准的计算机辅助设计模型直接分层不依赖任何特定的计算机辅助设计系统,通用性、灵活性好,而且产品模型数据交换标准文件的数据量大大小于STL文件,有利于网络化设计与制造环境下的数据传输与交换。     

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 from PowerSHAPE Models for Rapid Prototyping

Rapid prototyping processes produce parts layer by layer directly from CAD models. An efficient method is required to slice the geometric model of a part into layers. Several slicing methods are introduced in this paper: slicing from STL files; tolerate-errors slicing; adaptive slicing; direct slicing; adaptive and direct slicing. PowerSHAPE is a powerful package for building models, and it provided macro language and picture files for its secondary development work. To meet rapid proto-typing slicing demands, the author proposes a direct slicing approach based on PowerSHAPE models. In this method, lines, arcs and Bezier curves are used to describe the section contours. This approach can be used in stereolithography, selective laser sintering, fused deposition modelling, and other rapid prototyping processes, e.g. laminated object manufacturing. It may be the future solution to existing slicing problems.     

Dexel-Based Direct Slicing of Multi-Material Assemblies

Slicing is an important procedure in rapid prototyping (RP) pre-processing, and can be grouped into two categories: direct slicing and adaptive slicing. At present, investigations into the use of both direct and adaptive slicing methods are taking place. However, not many direct slicing approaches have been reported in the literature. The methods are also restricted to some solids in CSG or some CAD systems. Also, approaches on adaptive slicing are too complicated. The method proposed in this paper employs dexel encoding for direct slicing multi-material (MM) assemblies in RP. One advantage of using a dexel model is that Boolean operations can be performed simply on 1D line segments. Dexels can also be easily converted to tool paths in RP machines. Compared to the ray representation of CSG trees, dexel models can be extended to represent MM assemblies with material properties. Therefore, the method has high potential for direct slicing. In this paper, traditional dexel models are first extended for rapid manufacturing single solid and MM assemblies. Compared to other adaptive slicing approaches, a much more efficient and simple dexel model, for adaptive refinement in the building direction is then developed. To further improve the surface finish, a layerwise refinement approach is also discussed. Finally, the computational complexity of the proposed method is studied.     

<Emphasis Type="Bold">Curl Distortion Analysis During Photopolymerisation of Stereolithography Using Dynamic Finite Element Method</Emphasis>

Stereolithography is one of the rapid prototyping processes which uses a photopolymer as the raw material to build prototypes. The photopolymer absorbs energy by selective laser exposure. The curing effect starts when the absorbing energy exceeds a critical value, and the process is called photopolymerisation. The photopolymerisation changes the phase from liquid to solid. The cured volume can expand and then shrink on cooling. The process parameters such as the scanning speed, scanning path, scanning pitch, and the slicing thickness, lead to different shrinkage and curl distortion, so, the photopolymerisation process is a dynamic material behaviour. In this study, a dynamic finite element simulation code has been developed to simulate the photopolymerisation process. The simulated result for a suspended beam which corresponds to the process parameters shows that a short raster causes less curl distortion than a long raster. The experimental result agrees very well with the simulated result.     

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.     

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     

连续性对快速成形制造影响的研究

将实体几何连续性应用于快速分层 ,可以降低内存 ,加快信息提取时间。另外 ,沿垂直于Z向将巨型STL格式文件分割成多个STL格式文件 ,依次成型 ,可以避免巨型STL格式文件的读入错误和手工粘结带来的误差 ,提高了制件精度     

基于光成型的快速模具制造技术

阐述了用成型原理制造模具的几种技术。这些技术工艺过程简单，生产周期短，产品成本低，不需专用设备和工具，与并行工程相结合将为模具技术发展创造最佳条件。适合于快速生产形状复杂的精密模具，具有广泛的应用前景。     

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.