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Additive

Rapid prototyping processes have inherent errors due to layer-by-layer manufacturing and discrete slicing of 3D models. Errors occur during data preparation from tessellation and stair-stepping approximations. Process parameters and part orientation also influence accuracy. After building, finishing techniques like sanding can further impact dimensions. Proper file repair and optimization of factors like build orientation can help reduce inaccuracies in final prototypes.

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Janardhan Ganniga
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87 views35 pages

Additive

Rapid prototyping processes have inherent errors due to layer-by-layer manufacturing and discrete slicing of 3D models. Errors occur during data preparation from tessellation and stair-stepping approximations. Process parameters and part orientation also influence accuracy. After building, finishing techniques like sanding can further impact dimensions. Proper file repair and optimization of factors like build orientation can help reduce inaccuracies in final prototypes.

Uploaded by

Janardhan Ganniga
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Rapid Prototyping Process

Optimisation

Factors Influencing Accuracy


❑ Errors during the data preparation
stage such as STL file generation
model slicing
❑ part build direction
❑process specific parameters
❑part finishing techniques
Data Preparation
Errors due to Tessellation

Chord Height
Angle Control.
Suppose a model with overall dimensions of
250x250x250 mm has a round corner with a radius of
1 mm.
The results of tessellating the model by applying
Chord Heights of 0.5 and 0.05 mm respectively are
shown in Figure
Unfortunately, the increase of Chord Height leads not
only to smoother surfaces but also to larger data files.
RP processes have a stair-stepping problem that is found in
all layer manufacturing
technologies. Stair-stepping is a consequence of the
addition of material in layers.
As a result of this discrete layering, the shape of the original
CAD models in the
build direction (z) is approximated with stair-steps. This
type of error is due to the
working principles ofRP processes, which can be assessed in
data preparation.
The error due to the replacement of a circular arc with stair-steps is illustrated
The slicing error can be defined as

where ,
a is the angle between the chord and the horizontal axis, and
hchord is the chord height.
When slicing a STL file, the error consists of the
tessellation error hchord and the cusp height error .
The maximum errors happen with chords that have the
smallest values of a,
Different process-specific errors occur during part building.
For example, material shrinkage and control errors are the
most significant factors influencing the part
accuracy when thermal RP processes are employed, e.g. SLS,
MJM, FDM, LENS, etc. On the other hand, curing and
control errors are the main factors in RP processes
such as SL and SGC. In this section, specific part building
errors resulting from SL and SLS processes are discussed.
Part Building Errors in the SL Process
Over-curing.
Scanned lin
e shape
Control errors

Over-curing effects on accuracy (a - thicker bottom


layer, b -deformed hole boundary)
Scanned line cross section

Vertical wall
Effects on curves
Building Errors in the SLS Process

The main cause of part inaccuracy is the shrinkage during


sintering which does not always occur in a uniform manner.
The shrinkage of a new layer can be constrained by the existing
part substrate or by support powder trapped within enclosed
areas.
scaling a three-dimensional faceted file uniformly is not a
simple task and the resulting geometry can be slightly
deformed compared to the nominal geometry
new dimension = a (desired dimension) + b
Part Finishing
Varying amount of material.
Finishing technique.
During the data preparation stage, the RP model
shapes are approximated with the corners of the stair-
steps.
Each RP process reproduces the corners and the stair-
steps with a different resolution.
Also, the amount of material to be
removed on surfaces of the same model can vary due to
the selected part build
Selection of Part Build
Orientation
Finishing technique
wet and dry sanding, sand blasting, coating, spraying,
infiltration with special solutions, machining, etc.
The techniques that assure better dimensional control during
the finishing operation will have less impact on model
accuracy.

For instance, models finished employing milling will have less


influence on accuracy than those using manual wet sanding or
sand blasting.
Orientation Constraints of the SL Process

These constraints are defined by the technological capability


of the process, in particular the achievable build accuracy in
the X-Y plane and Z direction, and the necessity for support
structures for overhanging areas.
Following feature constraints should be considered in choosing
candidate build orientations for the SL process
User specified critical surfaces:
If these surfaces are planes, they have to be
placed such that their normals point in the build direction
are horizontal and upward facing.
Cylinders, cones and surfaces of revolution
are orientated so that their axes are vertical.

• Coordinate systems:
It is placed so that the z-axis points in the build direction.

Holes: In order to avoid hard-to-remove supports and stair-


stepping inside holes, these are placed orthogonally to
horizontal planes.
Cuts: If these carve through the part entirely or have a depth greater
than a certain minimum, the planes which they cut through
(placement planes) are made horizontal. Otherwise, they are
ignored.

• Shafts: These are orientated such that their placement planes are
horizontal in order to provide the best external surface finish.

• Protrusions: If these are created by revolving a section, the axes are


positioned. so that they are vertical.
Shells: These are orientated so that the concave part of the shell
faces upwards in order to minimise internal supports.
However, if the part is built on an older SL
system employing the deep-dip recoat method, this
orientation should be avoided as it would produce a trapped
volume
• Axes: All axes are placed so that they are vertical.
Software for RP
STL Standard Tessalation Language )is a stereolithography
CAD software created by 3D Syatems
STL describes only surface geometry of a 3 dimensional object
STL format specifies both ASCII and binary representation
It can be represented using 12 triangles
Z
Z y Y

STL Manupalation Solution Software


Fixing those models in order to produce watertight models.
Performing several simple actions to change the model
Magic RP
meshlab
Online fixing Services
Netfabb cloud service :
STL fix by Materialise:

Common Errors in CAD to STL conversion


Inverted Normal:
Zero thickness
Bad edges
Near bad edges
Real bad edges
Inverted Normal:
One surface does not have consistent
direction
bOx has one surface with
inverted normal

Zero thickness
Files should have volume larger than zero
Bad edges:
➢ If there is a gap b/n triangles i.e. referred as bad edges
➢Two hemisphere of the shape are no connected and
are marked with yellow line to indicate this
➢Stiching
Near bad edges
If the triangles are closer than the minimum threshhold
An mark is made
Real Bad Edges:
Enclose a hole in the shape
Complex
Zero thickness

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