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Lecture 1 3D Print - Intro STL Format

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42 views

Lecture 1 3D Print - Intro STL Format

Uploaded by

lohiaharsh2604
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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ME F315: Advanced MP

Additive Manufacturing
Additive vs. Subtractive

Hoyasaleshwara, KA (1121-1160 CE) Blisk (Modern Era)

Human Body Ovenbird Nest


Additive Manufacturing
Additive manufacturing (AM) is an automated fabrication process where
an object is realized layer-by-layer. AM integrates two main sub
processes: the physical making of each single layer and the joining of
subsequent layers in sequence to form the part. The AM build process
just requires the 3D data of the part, commonly called the virtual
product model.

CAD Model Slicer AM Machine


Support Structure

Scaffolding

• Some AM processes use model material with sparse deposition as support


• Some AM processes use separate sacrificial materials
• Some AM processes have inherent support materials
Part Structure
STL Format
• For each triangle , there are 7 lines

• Only the XYZ need to change for each triangle and these lines are
“copy” and “pasted” in editor to generate multiple lines for entire
solid.
STL File Format
3D printing uses STL (Standard Tessellation Language) file.

•Compatibility: STL files are compatible with nearly all 3D printers and
CAD programs.
•Size: STL files are smaller than other formats because they don't
include colour or texture information.
•Speed: STL files are faster to process than other formats.
•Ease of use: STL files are easier to convert into 2D slices that can be
laid down in succession.
•Rapid prototyping: STL files were originally designed to quickly
create scale models for rapid prototyping.
AM: STL
• STL (STereoLithography) created by 3D Systems.
• STL is also called as Standard Tessellation Language or standard
transformation language.
• An STL file describes a raw unstructured triangulated surface by
the unit normal and vertices (ordered by the right-hand rule) of
the triangles using a three-dimensional Cartesian coordinate
system.
• STL files describe only the surface geometry of a three
dimensional object without any representation of color, texture
or other common CAD model attributes.
• This file format is supported by many other software packages; it
is widely used.
• The STL format specifies both ASCII and binary representations.
• Binary files are more common, since they are more compact.
STL Format
STL File Issues
• Several problems plague STL files and they are due to the very nature
of STL files as they contain no topological data.
• Software creates polygonal approximation models.
• Types of errors:
• Gaps (cracks, holes, punctures) – missing facets
• Inverted normals
• Bad edges
o Near bad edges and
o Bad contours (holes)
• Shells
o Noise shells and
o Intersecting shells
• Overlapping triangles
• Intersecting triangles
STL File Issues
STL File Issues
STL File Issues
Multiple shell and nested parts
STL File Issues
Additive Manufacturing
• Produce parts by physically making and joining volume elements,
commonly called voxels. The volume elements are generally layers of
even thickness. Voxels are to 3D what pixels are to 2D.
• Modern computers are simply not optimized to handle rendering
voxels. Most of our hardware is meant to render polygons.
• Voxels are used in many scientific disciplines to quickly determine
volumetric data.

Voxels

Pixels
AM: Work Flow
Benefits of AM
• No specific tooling required.
• The material properties of part are generated during build process.
• Built in any imaginable orientation. No need for clamping. But need
support structures.
• Direct Assemblies can be printed.
• Mass Customization
• All AM processes uses the same so-called STL data structure, thus
eliminating data exchange problems.
• Scaling can be done simply in the CAD file, parts of different sizes &
made from different materials can be obtained from same data set.
• The range of materials includes foundry sand, acrylic resin, starch
powder, metals, and epoxy resin.
• Allows manufacturing of geometric details.
AM: Scaling and Materials
Disadvantages of AM
Stair-step Effect
The stair-step effect is a typical characteristic of the additive manufacturing process that
can never be entirely eliminated but can be reduced by decreasing the layer thickness.

Stepped surface as a result of the layering process. Three-dimensional solid model (left)
with marked equidistant layers and the created layer model (right) (Source: FH-Aachen)
Disadvantages of AM
Uprooting of Supports
Rapid Prototyping
• RP is an application of AM/3DP technology to make prototypes,
models, & mock-ups, all of them being physical parts but not products.
• They only mimic isolated properties of the latter product in order to
verify the engineering design and to allow the testing of selected
product capabilities and thus to improve and speed up the product
development process. Testing of the car’s climate control

show-
and-tell
models
Classification of AM Processes
Classification based on ISO/ASTM 52900

(1) Material extrusion


(2) Vat photopolymerization
(3) Powder bed fusion
(4) Binder jetting
(5) Material Jetting
(6) Direct Energy Deposition
(7) Sheet lamination
Thanks

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