• Journal of the Korean Society for Precision Engineering
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• v.17 no.1
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• pp.185-191
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• 2000

Direct ＆ adaptive slicing of sculptured surfaces in RP improves, quality ＆ accuracy of the final product, compared to the slicing with uniform layer thickness or the slicing of facets (ie, STL). Present D＆A slicing procedures adaptively compute the next layer thickness based on the surface information of current sliced contour, which assumes constant normal curvature values. In some cases, however. such assumption leads to intolerable slicing result which cannot correctly consider the entire local feature shape. We propose improved adaptive slicing algorithms which can determine near-optimal layer thickness, including illustrated examples.

• International Journal of Precision Engineering and Manufacturing
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• v.8 no.3
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• pp.64-70
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• 2007

Of all the rapid tooling (RT) methods currently available, thick-layer laminated tooling is the most suitable for large-scale, low-cost dies and molds. Currently, the determination of a lamina's contour or profile and the associated slicing algorithms are based on existing rapid prototyping (RP) data manipulation technology. This paper presents a new adaptive slicing algorithm developed exclusively for profiled edge laminae (PEL) tooling PEL tooling is a thick-layer RT technique that involves the assembly of an array of laminae, whose top edges are simultaneously profiled and beveled using a line-of-sight cutting method based on a CAD model of the intended tool surface. The cutting profiles are based on the intersection curve obtained directly from the CAD model to ensure geometrical accuracy. The slicing algorithm determines the lamina thicknesses that minimize the dimensional error using a new tool shape error index. At the same time, the algorithm considers the available lamination thicknesses and desired lamina interface locations. We demonstrate the new slicing algorithm by developing a simple industrial PEL tool based on a CAD part shape.

• Transactions of Materials Processing
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• v.27 no.5
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• pp.314-322
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• 2018

AlSi12 is a heat-resistant aluminum alloy that is lightweight, corrosion-resistant, machinable and attracting attention as a functional material in aerospace and automotive industries. For that reason, AlSi12 powder has been used for high performance parts through 3D printing technology. The purpose of this study is to observe deposition characteristics of AlSi12 powder in a direct energy deposition (DED) process (one of the metal 3D printing technologies). In this study, deposition characteristics were investigated according to various process parameters such as laser power, powder feed rate, scan speed, and slicing layer thickness. In the single track deposition experiment, an irregular bead shape and balling or humping of molten metal were formed below a laser power of 1,000 W, and the good-shaped bead was obtained at 1.0 g/min powder feed rate. Similar results were observed in multi-layer deposition. Observation of deposited height after multi-layer deposition revealed that over-deposition occurred at all conditions. To prevent over-deposition, slicing layer thickness was experimentally determined at given conditions. From these results, this study presented practical conditions for good surface quality and accurate geometry of deposits.

• International Journal of CAD/CAM
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• v.4 no.1
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• pp.33-45
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• 2004

In this work, a rational procedure has been formulated for the selection of points approximating slice contours cut in LOM (Laminated Object manufacturing) with first order approximation. It is suggested that the number of points representing a slice contour can be 'minimised' or 'optmised' by equating the horizontal chordal deviation (HCD) to the user-defined surface form tolerance. It has been shown that such optimization leads to substantial reduction in slice height calculations and NC codes file size for cutting out the slices. Due to optimization, the number of contour points varies from layer to layer, so that points on successive layer contours have to be matched by four sided ruled surface patches and triangular patches. The technological problems associated with the cutting out of triangular patches have been addressed. A robust algorithm has been developed for the determination of slice height for optimum and arbitrary numbers of contour points with different strategies for error calculations. It has been shown that optimisation may even lead to detection and appropriate representation of elusive surface features. An index of optimisation has been defined and calculations of the same have been tabulated.

• Journal of the Korea Computer Graphics Society
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• v.22 no.5
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• pp.17-26
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• 2016

This paper presents an adaptive slicing method based on merging vertical layer polylines. Firstly, we slice the input 3D polygon model uniformly with the minimum printable thickness, which results in bounding polylines of the cross section at each layer. Next, we group a set of layer polylines according to vertical connectivity. We then remove polylines in overdense area of each group. The number of layers to merge is determined by the layer thickness computed using the cusp height of the layer. A set of layer polylines are merged into a single polyline by removing the polylines within the layer thickness. The proposed method maintains the shape features as well as reduces the printing time. For evaluation, we sliced ten 3D polygon models using our method and a global adaptive slicing method and measured the total length of polylines which determines the printing time. The result showed that the total length from our method was shorter than the other method for all ten models, which meant that our method achieved less printing time.

• Proceedings of the Korean Operations and Management Science Society Conference
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• 2000.04a
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• pp.724-727
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• 2000

Rapid Prototyping(RP)이란 3차원 솔리드 모델을 단면화한 뒤 하나씩 적층하는 가공방식을 총칭한다. 이때 단면화하는 방법에 따라서 uniform, adaptive slicing으로 나뉘며, 입력 모델에 따라서 direct slicing과 STL을 이용한 방식으로 나뉜다. 적층 방법에 따라서는 연속된 2D 윤곽을 기반으로 적층하는 vertical layer 방식과 인접한 두 개의 2D 윤곽들을 연결하며 만들어진 3D layer를 기반으로 가공하는 sloping layer방식으로 나뉠 수 있다. 현재 상용 RP 시스템들에서는 거의 모든 경우 vertical layer 방식이 채택되어 사용되고 있다. RP와 절삭 공정, 예를 들면 CNC 밀링의 장점을 효율적으로 결합하기 위해서는 임의의 복잡한 형상을 갖는 솔리드 모델을 정밀도에 제한이 없이 제조할 수 있어야 한다. 그러나 절삭 공정은 특별한 전문적 지식들을 필요로 한다 또한 상용 RP에서 사용하는 순차적인 적층 작업으로는 가공할 수 없는 형상들이 많다. 대표적인 것으로 지지대를 필요로 하는 형상들이 있다. 이러한 형상들을 지원하기 위해서는 복잡한 3D 형상을 절삭 가능한 형식으로 분할하는 것과 적층 가능한 순서대로 공정 계획하는 것이 필요하게 된다. 본 연구에서는 SDM에서 제시된 3D 분할 방법이 솔리드 모델을 기반으로 전개되어 STL file과 같은 삼각다면체 형식으로 근사화된 모델에 적용하기 어렵다는데 착안하여 STL file에서 읽어들인 삼각 다면체 모델을 가공 가능한 3D 형상으로 분할하는 알고리즘을 제시하고자 한다.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.264-267
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• 2005

A subregional slicing method (SSM) is proposed to increase the nanofabrication efficiency of a nano-stereolithography (NSL) process based on two-photon polymerization (TPP). The NSL process can be used to fabricate 3D microstructures via the accumulation of layers of uniform thickness; hence, the precision of the final 3D microstructure depends on the layer thickness. The use of a uniform layer thickness means that, to fabricate a precise microstructure, a large number of thin slices is inevitably required. leading to long processing times. In the SSM proposed here, however, the 3D microstructure is divided into several subregions on the basis of the geometric slope, and then each of these subregions is uniformly sliced with a layer thickness determined by the geometric slope characteristics of each subregion. Subregions with gentle slopes are sliced with thin layer thicknesses, whereas subregions with steep slopes are sliced with thick layer thicknesses. Here, we describe the procedure of the SSM based on TPP, and discuss the fabrication efficiency of the method through the fabrication of a 3D microstructure.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.898-902
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• 1995

STEP is a neutral model for exchanging CAD modelbetween different CAD systms. The paper presents a laser path contour generation for rapid prototyping originated form STEP format files without using any tools nor libraries for STEP data manipulation. Polygons are generated from every point on the layer of given thickness, which are the intersections of layer plane and edges stored in entity tables. Curves are approximated with polygons whitin segment tolerance limit in order to cover sculptured surfaces. With the advantage of less data loss in direct slicing over STL formats, the system developed in this work shows a good potential to provide data share with various CAD systems including RP data preparation.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1996.04a
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• pp.587-591
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• 1996

Usually triangular patches are used to transfer geometric shape in Rpaid Prototyping CAM system. STL, a list of triangles, is de facto in RP industry. Because STL has no topology data, it can cause errornous results. So, STL should be verified before using. After adding support structures to anchor the part to the platform and to prevent sagging or distortion, slicing and layer by layer manufacturing process are done. But triangular patch is surface model and cannot provide dufficient information on geometry in the above processes. So, geometric modeling is necessary in verifying STL, adding support structures, and slicing. It is natural that triangle based modeling is the best when traingular patches are used as input. Considering support structures, solid and faces coexist in RP process. Therefore non-manifold modeler is required. In this study, triangle based non-manifold geometric modeling is proposed for RP system consitent with STL input.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.2
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• pp.136-144
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• 1997

Usually triangular patches are used to transfer geometric shape in Rapid Prototyping CAM system. STL, a list of triangles, is de facto standard in RP industry. Because STL does not have topological infoma- tion, it can cause errornous results. So STL should be verified before using. After adding support structures to anchor the part to the platform and to prevent sagging or distortion, slicing and layer by layer manufactur- ing process are done. But triangular patch is surface model and cannot provide sufficient information on geometry in the above processes. So, geometric modeling is necessary in verifying STL, adding support structures and slicing. It is natural that triangle based modeling is the best when tringular patches are used as input. Considering support structures, solid and faces coexist in RP process. Therefore non-manifold modeler is required. In this study, triangle based non-manifold geometric modeling is proposed for RP sys- tem consistent with STL input.