WO2017141070A1 - Procédé et système de prototypage rapide par simulation virtuelle - Google Patents

Procédé et système de prototypage rapide par simulation virtuelle Download PDF

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WO2017141070A1
WO2017141070A1 PCT/IB2016/050816 IB2016050816W WO2017141070A1 WO 2017141070 A1 WO2017141070 A1 WO 2017141070A1 IB 2016050816 W IB2016050816 W IB 2016050816W WO 2017141070 A1 WO2017141070 A1 WO 2017141070A1
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Prior art keywords
hatch
layer
rapid prototyping
fabricated
toolpath
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PCT/IB2016/050816
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English (en)
Inventor
Amar PHATAK
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Phatak Amar
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Priority to PCT/IB2016/050816 priority Critical patent/WO2017141070A1/fr
Publication of WO2017141070A1 publication Critical patent/WO2017141070A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/20—Design optimisation, verification or simulation
    • G—PHYSICS
    • G16—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR SPECIFIC APPLICATION FIELDS
    • G16H—HEALTHCARE INFORMATICS, i.e. INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR THE HANDLING OR PROCESSING OF MEDICAL OR HEALTHCARE DATA
    • G16H50/00—ICT specially adapted for medical diagnosis, medical simulation or medical data mining; ICT specially adapted for detecting, monitoring or modelling epidemics or pandemics
    • G16H50/50—ICT specially adapted for medical diagnosis, medical simulation or medical data mining; ICT specially adapted for detecting, monitoring or modelling epidemics or pandemics for simulation or modelling of medical disorders

Definitions

  • This invention belongs to the field of computer-implemented techniques for design, simulation and evaluation of component build and/ or process execution and in that, relates generally to methods and systems capable of allowing rapid prototyping via virtual simulation.
  • the present invention is a software-enabled tool for digital modeling of the form and behavior of real-world materials and processes intended as a precedent to real-world implementation of progressive (additive or subtractive) manufacturing technologies commonly employed for modelling, prototyping, and production applications.
  • framework environments and their effect on aforesaid considerations, must also be ably factored in while determining the considerations to be applied.
  • a physical build trial-and-error approach would be too time-consuming as well as grossly error-prone in this parlance, it is crucial to have some means for accurately mapping and emulating dynamics of considerations to be applied in order to allow rapid prototyping and/ or optimization of industrial processes intended, preferably without involving the errors, run-economics, constraints and thus the redundancy of manual processing in real-world environments.
  • Virtual modeling holds distinct promise for addressing the needs voiced above.
  • Virtual models form a software-only representation of a component or manufacturing environment which, taken step at a time, allows simulation of the manufacturing process involved in a given set of design considerations and thus achieve greater control over the output intended while reducing the number of iterations and associate resource costs in design-prototype-test cycles.
  • traditional approaches with such intend have been observed to be entirely complex to learn, awkward to use, and often provide only marginal benefits in allowing rapid prototyping.
  • the performance of rapid prototyping processes is affected by multitude process parameters such as layer thickness, hatch spacing, temperature of working environment, scan speed, etc.
  • US20070288300 (filed by Vandenbogart Thomas William) introduces a method for rapidly producing a prototype includes the steps of conducting an interview of a participant in a product development study; presenting an item for review; providing physical sets of alternatives for components of the item; eliciting preference values for the alternatives from the participant; inputting the preference values into a computer software program; producing a virtual ideal item based on the preference values using the computer software program; and presenting the virtual ideal item to the participant.
  • the accompanying disclosure and claims are silent on sequential virtual run of the production run, do not provision for review, and do not preclude involvement of human user for feedback and listing of preferential values.
  • US20120083339 discloses a method for transforming a virtual object based on user input information including receiving by an input device a user input alpha-numeric input information, correlating, using one or more processors, the user input alphanumeric information with transformation of one or more characteristics of the virtual object, and transforming, using one or more processors, the one or more characteristics of the virtual object from a first configuration to a second configuration based on the correlated user input alpha-numeric information.
  • this innovation unilaterally focuses on rendering a virtual reality gaming user environment, and is silent on processivity of process parameter data critical for rapid prototyping.
  • US7840393 (issued to Trivascular, Inc) discloses a system and method of developing better-designed medical devices, particularly cardiovascular stents and endovascular grafts.
  • the system comprises a geometry generator, a mesh generator, a stress/strain/deformation analyzer, and a visualization tool.
  • the geometry generator receives three-dimensional volumetric data of an anatomical feature and generates a geometric model.
  • the mesh generator then receives such geometric model of an anatomical feature or an in vitro model and a geometric model of a candidate medical device.
  • the mesh generator only receives a geometric model of the candidate medical device.
  • the mesh generator uses the geometric model(s) received, creates or generates a mesh or a finite element model.
  • the stress/strain/deformation analyzer then receives the mesh, and the material models and loads of that mesh. Using analysis, preferably non-linear analysis, the stress/strain/deformation analyzer determines the predicted stresses, strains, and deformations on the candidate medical device. Such stresses, strains, and deformations may optionally be simulated visually using a visualization tool.
  • the accompanying disclosure and claims are silent on provision of user-selectable parameters / production-material specific parameters as well as simulation of production runs critically required for accurate rapid prototyping.
  • US6310619 (issued to Rice Robert W) discloses a three-dimensional, virtual reality, tissue specific model of a human or animal body which provides a high level of user-interactivity.
  • the model functions can be analyzed and user-modified on a tissue-by-tissue basis, thereby allowing modeling of a wide variety of normal and abnormal tissue attributes and corresponding study thereof.
  • the model can be user-modified through a keyboard, or other VR tools such as a haptic interface.
  • the haptic interface can modify the model to correspond to the tissue attributes of a user, and can provide sensory output corresponding to the interaction of the model to a pre- scripted scene.
  • the accompanying disclosure and claims do not provide an able manner in which the principles of this invention can be migrated to efficient operation of a manufacturing setup.
  • the means for rapid prototyping so provided is further capable of assessing productivity, product quality and material utilization besides outputting qualitative as well as quantitative assessment reports of operative run cycles for the end-product intended.
  • the means for rapid prototyping so provided is further capable of rendering real-time updated, interactive digital visualization of the process implementation in progress.
  • Figure 1 is a flow chart explaining the preferred mode of implementation of the present invention.
  • Figure 2 is a schematic diagram depicting various modules and their functions in implementation of the present invention.
  • Figure 3 are schematic illustrations of the slicing plane and contour in X-Y plane respectively.
  • Figure 4 is a screenshot of the contents of a sample sliced data file.
  • Figure 5 is a screenshot of the data structure of the sliced data file depicted in Figure 4.
  • Figure 6 is a schematic diagram to explain how minimum and maximum bounds or hatching are determined in the present invention.
  • Figure 7 is a schematic diagram to explain how Y intersection of an edge is determined in the present invention.
  • Figure 8 depicts the contents of an unordered hatch data file.
  • Figure 9 is a schematic diagram illustrating the zigzag toolpath established for a particular layer
  • Figure 10 is a schematic diagram illustrating the final toolpath established for a particular layer
  • Figure 1 1 is a top view of an actual hatch/dexel
  • Figure 12 illustrates the stairstep effect (error along Z direction)
  • Figure 13 (A and B) illustrate errors in X-Y plane in a partial scan, and full scan, respectively of a particular layer
  • Figure 14 is a schematic diagram illustrating how contour is approximated for a particular layer in the present invention.
  • Figure 15 is a schematic diagram illustrating how part quality in X-Y plane is determined for a particular part under fabrication in the present invention.
  • Figure 16 is a screenshot of the GUI for allowing user inputs to the system of the present invention.
  • Figure 17 is a screenshot of the GUI for allowing a user to visualize outputs of the system of the present invention.
  • Figure 18 is a screenshot depicting a complex shape (squirrel) being subject of simulated fabrication by system of the present invention.
  • Figure 19 is a screenshot depicting the report generated for shape depicted in Figure 18.
  • Figure 20 (A to D) are step-wise screenshots depicting various successive stages of the simulated fabrication of the shape depicted in Figure 18.
  • Figure 21 is a table depicting results of four iterations wherein process parameters are altered for simulated fabrication of the shape depicted in Figure 18
  • the present invention is directed towards a computer-implemented method for virtual prototyping for a rapid prototyping application such as SLS where sliced / process planning data is used as an input, based on which hatching data for a given part orientation, layer thickness and hatch space data for the SLS process intended.
  • Inventive algorithms subsequently run on said data to compute output process parameters such as part quality (surface roughness), overall process time for building a prototype, volume of material utilization and estimation of part shrinkage for a given set of process parameters, thereby resulting in an accurate virtual rendition of the manufacturing process, and final output.
  • process parameters such as part quality (surface roughness), overall process time for building a prototype, volume of material utilization and estimation of part shrinkage for a given set of process parameters, thereby resulting in an accurate virtual rendition of the manufacturing process, and final output.
  • the user can therefore freely experiment with various process parameters relating to part material, laser speed, slice layer data etc and estimate their effect on the resulting part produced in terms of productivity, part quality and economy (material).
  • a product model is the central element, which integrates all information about the product and links different phases of product development. Modeling of such product or development process by rapid prototyping essentially needs to determine and incorporate mathematical relationships of various process parameters concerned, which in cohesion, accurately predict final manifestation as well as influences on parts and materials involved.
  • a coupled virtual reality interface would thereby allow the designer to visualize and interact naturally with the virtual world in connection with each among the different phases of product development intended.
  • the present invention seeks to establish a novel approach for rapid prototyping by accurate process simulation with due consideration to part building and shrinkage issues.
  • the system so provided simulates the effect of process parameters on process outputs in the form of productivity, part quality and economy in terms of material required.
  • an illustrative virtual simulation of a run cycle initiates with execution of a set (001) of algorithms configured for preprocessing functions/ design considerations such as hatching and toolpath planning.
  • Output of set (001) is stored as a prototyping file (002).
  • processing parameters such as hatch space, layer recoating time, laser velocity, part bed temperature and laser power using a drop down menu or form illustrated in Figure 2, provided within the system user interface which lists an inventory of default or standard values but also allows the user to append custom values as required according to the process output intended.
  • the system can proceed with simulation (004) of the production run, by means of a graphical simulation module configured to report / display consecutively each step as would be implemented (005) in a real-world execution scenario.
  • the process is looped by decision functions (007) and (008) which allow unlimited opportunity for correct or evaluate alternative design considerations as required, until the desired/ satisfactory process or product is achieved. For example, first the powder layer is displayed, then toolpath information is read in and fabrication of the immediate layer is simulated by attaching dexels to the powder layer one at a time. After simulation for this layer is completed, another un-sintered powder layer is recoated and the simulation repeated till end of production run / completion of the product intended.
  • the system allows the user to apply necessary corrective measures by altering parameters at step (003) to thereby cause one more virtual execution of the production run.
  • decision function (008) a set (009, not shown in the accompanying drawings) of algorithms configured for post-processing functions such as part quality assessment, computation of build time and shrinkage estimation of fabricated part is integrated into system of the present invention. This allows virtualization of the entire production cycle and applying of varying design considerations till perfection without incurring the restraints of real-world application scenarios.
  • set (009, not shown in the accompanying drawings) of algorithms is configured to generate a display shown in Figure 3 or report on the virtual production run executed immediately before, thereby allowing a user to log, assess and take action in response to the extent of operational success thereby observed.
  • visibility is maintained throughout the fabrication process by integration of a transparency feature, which allows step-by-step articulation before a user in charge of the SLS process undertaken.
  • system user interface is configured to allow variable articulation of display generated during the simulation step (004) by advantageous integration of the Genetic Algorithm (GA) technique, whereby the user is able to rotate, translate and zoom in and out of the component being fabricated using mouse interaction.
  • GA Genetic Algorithm
  • the simulation step (004) mimics the form and behavior of real-world materials and processes, hence is useful in determining the build height, build time, part quality measurement and shrinkage of the material after solidification in the SLS process mentioned hereinabove, thereby allowing design, simulation and evaluation of component build and/ or process execution in a unified approach.
  • the fabricated virtual end-product may be further assessed for build-quality and utility as a mold for mass production.
  • Figures 4(a) and 4(b) respectively, it can be seen that products of complex geometry (20000 and 40786 facets respectively) and multiple morphological features can be rapidly prototyped virtually by performance of the present invention.
  • the present invention is intended as application primarily as a locally hosted/ downloadable software application. However alternatively, its implementation as a cloud-based service and/ or distributed hosting involving a thin client for users is also possible using state-of-art infrastructure which forms part of the public domain, and hence not described in detail herein to avoid obscuring the present invention.
  • the present invention thereby provides a virtual workbench for rapid prototyping processes, in which typically a process planning file, in other words the slice data, of the part to be fabricated is taken as a primary input. This input is then passed through a pre-processing module (parser) where the point data is stored and layer thickness is determined.
  • Process parameters for a typical rapid prototyping process such as SLS, including Hatch width/ hatch space in mm, Laser velocity in m/sec, Layer setup time(non-productive time) sees, Part bed temperature in degree C and Laser power in W are taken as input from the user as they are machine-specific.
  • the machine- specific parameters may be inputted manually by the user based on the specific machine available with the user or alternatively selected by the user conveniently using a drop-down menu based on standard catalogue data of various rapid prototyping machines available.
  • a hatching module determines the coordinates of the endpoints of each hatch line for virtual fabrication. The step over is taken as input for each pass in a layer. The hatch points are used by toolpath planning module to generate laser toolpath for each layer. Time required and the volume of the part fabricated are also estimated by toolpath planning.
  • a part quality module computes the peak height and valley depth for each hatch vector. It in turn estimates the quality of part fabricated across each layer in the X-Y (fabrication) plane. Shrinkage is derived empirically, output of which is expressed in terms of volume of the part fabricated thus accounting for shrinkage for a given set of process parameters. The system so developed thereby allows a user to experiment by varying process parameters and fine tune them to produce the parts with desired quality, productivity (build time) and economy (Material utilization).
  • Figure 3 (A) and (B) respectively show the typical STL facets with the slicing plane and contour generated in the sliced X-Y plane. This contour is stored in the sliced file in terms of coordinates of endpoints of edges wherein consecutive two points form one edge.
  • Figure 4 is a screenshot representing format of the sliced data file so reached. First two points forms one edge and the next two points forms another edge. The endpoints of edges for every layer are stored in sliced data file. However, first edge is not connected to the next edge i.e. edge connectivity is not present in the input file. All the edges present in one layer are randomly stored in the file.
  • a plurality of arraylists is used to store the sliced data as the size varies from file to file and even from layer to layer.
  • the input file is read twice.
  • the first pass number of layers is determined referring to the Z value of points. This determines the number of arraylist required.
  • the coordinates of the points present for a given layer is stored in an arraylist pointed by the layer number.
  • the coordinates of the following points are stored in the next arraylist pointed by the corresponding layer number. This continues till all the points are stored in slice file.
  • FIG. 5 illustrates the data structure for storing the sliced data so parsed.
  • the data structure stores the endpoints of the edges.
  • edge 1 of layer 1 is made up of endpoints (X1 .Y1 , Z1) and (X2, Y2, Z2).
  • the edge 2 will be made up of points (X3.Y3, Z3) and (X4, Y4, Z4).
  • the data structure will store only points such that the two consecutive points will form one edge of contour.
  • the parser also stores the layer number which points towards the corresponding points forming that contour. Edges need not to be stored.
  • SliceStoreO function is called where depending on the number of layers determined in first pass an array of arraylist is declared. Then for the particular layer number the points are stored in the dynamic arraylist.
  • Special purpose dynamic data types like arraylist from Java is used for efficient memory management.
  • Hatch pattern generation Required for toolpath generation, contour data from for each layer the prior step of input pre-processing is taken as a primary input. Machine-specific parameters being user defined, are taken as secondary input. Before initiating hatching, it is essential to identify the minimum and maximum bounds for a given contour. Hence, coordinates for each layer is passed to a function lengthO where minimum and maximum value of X coordinate are determined as shown in Figure 6. This is necessary for the determination of the First hatch and the Last hatch points, which are determined using the formulae:
  • Arraylist is used to store the hatch data as the number of hatch points is dynamic in nature. Each arraylist is pointed by the layer number. Data structure used is similar to the data structure of slice data file
  • Toolpath planning plans the path of travel of the laser over the powder layer in the rapid prototyping process (SLS). This module also determines the time required for the fabrication of the part and volume of the material utilized during fabrication from the toolpath planning.
  • the algorithm for the generation of toolpath is mainly divided into two components. First it sets the order of hatch points for each hatch vector. Then it generates the hatch pattern vectors where a sequential order is set for all the hatch vectors present in a given layer. Toolpath points are then stored. Zigzag pattern is used for the toolpath planning to reduce the time require for the fabrication of part. The steps are explained below: a.
  • the hatch points generated by hatching module are also not be in a sequential manner.
  • the points are stored randomly as shown in Figure 8.
  • the correct sequence is P1 -P3-P4-P2 as it is essential that the laser should not move to and fro in a single hatch line. Therefore it is necessary to set an order for hatch points within a single hatch vector. This task is carried out by orderO function of the toolpath class
  • a zigzag toolpath is generated by the function orderHatchQ of toolpath class.
  • hatch points are stored in an order.
  • next hatch line reverse ordering is done and then stored.
  • hatch points are stored in a forward order and so on. This alternate forward and reverse ordering gives to a zigzag toolpath as shown in Figure 9.
  • Final toolpath data is stored in a toolpathData file corresponding to a particular layer.
  • Tb Tp + Tnp (4)
  • Tb Total build time per layer
  • Tp Productive time
  • Tnp Layer setup time (6)
  • the total time require for part fabrication is given by:
  • volume of Material required When a laser sinters the powder along a hatch vector, rectangular box shape geometry is created in between the two hatch points. While at the end points due to the laser spot, semi cylindrical geometry is created. Hence the actual geometry of single hatch is not rectangular. The actual shape of hatch is as shown in Figure 1 1 . Hence the volume of single hatch is given by volume of rectangle and volume of one cylinder. While generating the toolpath the algorithm calculates hatch length of every single hatch. This length is used to calculate the volume of that hatch. Then the volume of next hatch is added to the previous volume. The volume of single hatch is given by:
  • Part quality refers to the smoothness of the surface produced. Part quality can be measured in two ways. Along Z direction (build direction) due to the layer by layer manufacturing of the part a stairstep effect is produced on the part as shown in Figure 12 whereas from Figure 13 (A and B), it can be seen that geometric errors generated in X and Y planes (build) are associated with the scan path, partial and full respectively, and the tool shape. Along X-Y plane a layer is manufactured by hatching. Hatching is in essence an approximation where each dexel, as shown in Figure 14, is approximately fitted in the contour of the layer.
  • part quality in X-Y plane is also affected by error similar to that of stairstep error for build direction.
  • Stairstep is calculated by comparing fabricated part with original CAD model. Calculation of geometric errors in X- Y plane is among the prime novel features of the present invention being unprecedented in prior art.
  • the developed system is able to estimate the quality of the part along X-Y plane for every layer.
  • Quality of the fabricated layer is estimated in terms of peak height, valley depth and peak to valley distance.
  • Figure 15 shows the typical geometrical error produced in the layer by the dexels. As seen here, a. Peak height refers to the upper deviation of the part fabricated from the original dimension. It specifies the amount of extra part sintered. Due to the cylindrical geometry of endpoints for the hatch, the part fabricated always has upper deviation. In any case the upper deviation will be equal to the radius of the laser spot
  • E Pea k is peak height error and R La serspot is radius of laser spot b.
  • Valley depth refers to the lower deviation from the original dimension.
  • valley depth the first point of joining of two dexels as shown in Figure 15 is determined. The distance of that point to the original dimension line gives the valley depth for those two dexels. The distance is calculated by c. Peak to valley distance is the addition of peak height and the valley depth. It gives the overall dimensional error.
  • Shrinkage estimation To estimate the shrinkage of a part model for a chosen set of process parameters, the system proposed herein takes Part Bed Temperature, Hatch Space, Laser Speed and Laser Power as inputs from the user. Shrinkage is predicted using conventional empirical formulae specific to materials used. System also takes toolpath data as an input from the toolpath module. From toolpath data, scan length for each dexel is calculated. For example, empirical formula (reported by Raghunath et al) for the determining the shrinkage scaling factor in X, Y and Z direction, for polyamide material is given by:
  • L P is the laser power in W
  • L s is the scan length in mm
  • B s is the beam speed in m/sec
  • H s is the hatch space in mm
  • T B is the part bed temperature in °C
  • the very first dexel of the part is free to shrink in all the three directions without any restrictions. This is because it is surrounded by air from the top and powder from all the remaining sides which does not restrict and allows free shrinkage.
  • the first dexel solidifies by that time and hence it provides restriction for the second dexel. Hence it does not shrink freely.
  • Remaining dexels are restricted along their length and along their heights. Hence these dexels will shrink less compared to first dexel. Hence, such case is considered while designing the shrinkage estimator for the current project for predicting more accurate results.
  • Shrinkage for the first layer is calculated by firstl_ayer() function of shrinkage class, which is further sub-divided to calculate shrinkage for the first dexel and the remaining subsequent dexels.
  • shrinkage in X (length), Y (width) and Z (height) direction is calculated and applied directly to the dexel and shrink volume is stored.
  • shrinkage in X Y and Z direction is calculated.
  • width (Y) there is no constraint for the dexels and hence it is directly applied.
  • shrinkage is restricted.
  • the mean value of shrunk dimension and original dimension is calculated and those mean values are the new dimensions of remaining dexels along length (X) and height (Z). Volumes of the dexels are calculated and added to give the overall shrunk volume of first layer
  • shrinkage of dexels will be restricted by the previous layer which will be solidified by the time second layer gets sintered.
  • the first dexel of every other layer will not experience restriction along its height as along its height it is surrounded by un- sintered powder which will cause no restriction as shown in Fig. 3.18.
  • First dexel of each layer will have free shrinkage along its height.
  • the remaining subsequent dexels of the considered layer will have restriction along all directions as they are surrounded by solid dexels along its length, height and width.
  • shrinkage for other layer is calculated by otherLayerO function from shrinkage.
  • first dexel shrinkage along length, width and height is calculated.
  • Shrinkage along height is directly applied as there is no constraint along height and along length and width there is constraint by previous layer.
  • mean value of shrunk dimension and original dimension is calculated and those mean values are the new dimensions of dexel along length (X) and width (Y).
  • Volume is then calculated for the first dexel and is added to previous volume.
  • mean value of shrunk dimension and original dimension is calculated for all along length, width and height as they are restricted along all direction as shown in Fig. 3.19.
  • Fabrication of the layer is simulated by attaching dexels to the
  • Un-sintered powder layer is represented with 96% transparent layer and dexel representation is done in suitable contrasting color for best visualization
  • Example 1 Squirrel design - Squirrel part model is selected for the case study because of its free form geometry.
  • the STL model of squirrel is shown in Figure 18, which has 20000 facets (verified with MeshLab v1 .3.0).
  • Figure 19 is a report detailing the input process parameters, and system outputs as obtained using method and computer-implemented system of the present invention for a defined set of materials and operating parameters.
  • MiniMagics 2.0 was used for validation of the volume of material required for the fabrication of part.
  • MiniMagics 2.0 gives the actual volume of the STL part model in mm 3 .
  • Actual volume of the STL squirrel part is 219.25mm 3 whereas, system estimate of volume of material required for part fabrication was 223.21 mm 3 Therefore, the system of the present invention quite fairly estimated the volume of the part fabricated.
  • Screen shots of graphical simulation of squirrel through various stages of virtually simulated fabrication are shown in Figure 20. By selecting different process parameters various system outputs were created and expressed in tabulated form as shown in Figure 21 , from which interrelationships and influences on productivity, product quality and economy expected in a real world environment with respect to variability in process parameters, component wear, toolpath planning, and material behavior can be easily marked.
  • the present invention is thus targeted primarily at Selective Laser Sintering (SLS) processes, however localization for Stereolithography (SLA), Fused Deposition Modeling (FDM), Laminated Object Manufacturing (LOM) and Solid Ground Curing (SGC) processes, and their incremental forms is intended as natural evolution of the present invention in coming time.
  • SLA Stereolithography
  • FDM Fused Deposition Modeling
  • LOM Laminated Object Manufacturing
  • SGC Solid Ground Curing

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Abstract

La présente invention concerne un procédé informatique de virtualisation de processus de prototypage rapide qui permet à un utilisateur d'envisager avec précision une opération de fabrication et une sortie de produit fini à obtenir, avec une prise en compte précise d'interpénétrations et d'influences sur la productivité, la qualité des produits et l'économie prévue dans un environnement du monde réel par rapport à la variabilité des paramètres de processus, de l'usure des composants, de la planification de chemin d'outils, et du comportement des matériaux.
PCT/IB2016/050816 2016-02-16 2016-02-16 Procédé et système de prototypage rapide par simulation virtuelle WO2017141070A1 (fr)

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CN111819505A (zh) * 2018-02-05 2020-10-23 创真私人有限责任公司 用于打印3d对象的打印机
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CN118468369A (zh) * 2024-05-23 2024-08-09 湖南城市学院 一种包装图形自动生成方法及系统

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