Universal and efficient hybrid modeling and direct slicing method for additive manufacturing processes

doi:10.1007/s40436-023-00468-8

Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (2): 300-316.doi: 10.1007/s40436-023-00468-8

• • 上一篇

Universal and efficient hybrid modeling and direct slicing method for additive manufacturing processes

Sen-Lin Wang¹, Li-Chao Zhang¹, Chao Cai¹, Ming-Kai Tang², Si Chen¹, Jiang Huang¹, Yu-Sheng Shi¹

1 State Key Laboratory of Materials Processing and Die and Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, People's Republic of China;
2 School of Machinery and Automation, Wuhan University of Science and Technology, Wuhan 430081, People's Republic of China

收稿日期:2023-02-27 修回日期:2023-05-05 发布日期:2024-05-16
通讯作者: Li-Chao Zhang,E-mail:zlc@hust.edu.cn E-mail:zlc@hust.edu.cn
作者简介:Sen-Lin Wang is a doctoral candidate at the School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, China. His research interests include material-structure-process-performance-integrated additive manufacturing data processing, and additive manufacturing CAD/CAM algorithms;
Li-Chao Zhang received his B.Sc. and Ph.D. degrees from the Huazhong University of Science and Technology in 1998 and 2002, respectively. He is currently an associate professor and doctoral supervisor at the School of Materials Science and Engineering, Huazhong University of Science and Technology in Wuhan, China. His research interests include software and control systems in advanced manufacturing fields, such as additive manufacturing and intelligent manufacturing;
Chao Cai received his B.Sc. degrees from the Wuhan University of Technology and Ph.D. from the Huazhong University of Science and Technology in 2012 and 2017, respectively. He is currently an associate professor and doctoral supervisor at the School of Materials Science and Engineering, Huazhong University of Science and Technology in Wuhan, China. His research interests include hot isostatic pressing and additive manufacturing of complex high-performance components;
Ming-Kai Tang received his B.Sc. degrees from Hubei University of Technology and PhD degrees from Wuhan University of Technology in 2011 and 2017, respectively. He is currently a lecturer at the School of Machinery and Automation at the Wuhan University of Science and Technology. His research interests focus on selective laser melting;
Si Chen is a master's degree candidate at the School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan. His research interests include path planning for multiaxis additive manufacturing;
Jiang Huang is a master's degree candidate at the School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan. His research interests include supporting structure-generation algor it hms for additive manufacturing;
Yu-Sheng Shi received his B.Sc. and Ph.D. degrees from China University of Geosciences (Wuhan) in 1984 and 1996, respectively. He is currently a professor and a doctoral supervisor at the School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, China. His research interests include advanced manufacturing technologies, such as additive manufacturing and 4D printing.
基金资助:
This work was supported by the Key Area R&D Program of Guangdong Province(Grant No.2020B090924002) and the National Natural Science Foundation of China(Grant No.51790174).

Universal and efficient hybrid modeling and direct slicing method for additive manufacturing processes

Sen-Lin Wang¹, Li-Chao Zhang¹, Chao Cai¹, Ming-Kai Tang², Si Chen¹, Jiang Huang¹, Yu-Sheng Shi¹

1 State Key Laboratory of Materials Processing and Die and Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, People's Republic of China;
2 School of Machinery and Automation, Wuhan University of Science and Technology, Wuhan 430081, People's Republic of China

Received:2023-02-27 Revised:2023-05-05 Published:2024-05-16
Contact: Li-Chao Zhang,E-mail:zlc@hust.edu.cn E-mail:zlc@hust.edu.cn
Supported by:
This work was supported by the Key Area R&D Program of Guangdong Province(Grant No.2020B090924002) and the National Natural Science Foundation of China(Grant No.51790174).

摘要/Abstract

摘要： Model design and slicing contour generation in additive manufacturing (AM) data processing face challenges in terms of efficiency and scalability when stereolithography files generated by complex functionally graded structures have millions of faces. This paper proposes a hybrid modeling and direct slicing method for AM to efficiently construct and handle complex three-dimensional (3D) models. All 3D solids, including conformal multigradient structures, were uniformly described using a small amount of data via signed distance fields. The hybrid representations were quickly discretized into numerous disordered directed lines using an improved marching squares algorithm. By establishing a directional HashMap to construct the topological relationship between lines, a connecting algorithm with linear time complexity is proposed to generate slicing contours for manufacturing. This method replaces the mesh reconstruction and Boolean operation stages and can efficiently construct complex conformal gradient models of arbitrary topologies through hybrid modeling. Moreover, the time and memory consumption of direct slicing are much lower than those of previous methods when handling hybrid models with hundreds of millions of faces after mesh reconstruction.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00468-8

关键词: Additive manufacturing (AM), Hybrid modeling, Direct slicing, Signed distance field

Abstract: Model design and slicing contour generation in additive manufacturing (AM) data processing face challenges in terms of efficiency and scalability when stereolithography files generated by complex functionally graded structures have millions of faces. This paper proposes a hybrid modeling and direct slicing method for AM to efficiently construct and handle complex three-dimensional (3D) models. All 3D solids, including conformal multigradient structures, were uniformly described using a small amount of data via signed distance fields. The hybrid representations were quickly discretized into numerous disordered directed lines using an improved marching squares algorithm. By establishing a directional HashMap to construct the topological relationship between lines, a connecting algorithm with linear time complexity is proposed to generate slicing contours for manufacturing. This method replaces the mesh reconstruction and Boolean operation stages and can efficiently construct complex conformal gradient models of arbitrary topologies through hybrid modeling. Moreover, the time and memory consumption of direct slicing are much lower than those of previous methods when handling hybrid models with hundreds of millions of faces after mesh reconstruction.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00468-8

Key words: Additive manufacturing (AM), Hybrid modeling, Direct slicing, Signed distance field

Sen-Lin Wang, Li-Chao Zhang, Chao Cai, Ming-Kai Tang, Si Chen, Jiang Huang, Yu-Sheng Shi. Universal and efficient hybrid modeling and direct slicing method for additive manufacturing processes[J]. Advances in Manufacturing, 2024, 12(2): 300-316.

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Universal and efficient hybrid modeling and direct slicing method for additive manufacturing processes

Universal and efficient hybrid modeling and direct slicing method for additive manufacturing processes

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