Build orientation becomes a hot issue in 3D printing, which has a significant impact on the surface quality, support structure and final cost of the fabricated model. In this paper, we focus our attention on the surface quality of the part when fabricated by a 3D printer under certain specific build orientation. A novel method using curvature shift is proposed to search local regions with obvious curvature changes of the model printed. Based on curvature shift strategy, the model is divided into separate regions which can be treated differently. Every triangle facet of the regions is given different weight factor by calculating the average curvature of each region. Weighted facets is introduced in building volume error function. Candidate build orientation can be obtained by the eigenvalue decomposition and the optimal build orientation is the one which leads to the minimal error of the function. From the case study, the method proposed gets a smaller error with a lower printing cost and time, which means the model surface in higher weighted regions gets a higher surface quality when printed.
This study presents a robustness optimization method for rapid prototyping (RP) of functional artifacts based on visualized computing digital twins (VCDT). A generalized multiobjective robustness optimization model for RP of scheme design prototype was first built, where thermal, structural, and multidisciplinary knowledge could be integrated for visualization. To implement visualized computing, the membership function of fuzzy decision-making was optimized using a genetic algorithm. Transient thermodynamic, structural statics, and flow field analyses were conducted, especially for glass fiber composite materials, which have the characteristics of high strength, corrosion resistance, temperature resistance, dimensional stability, and electrical insulation. An electrothermal experiment was performed by measuring the temperature and changes in temperature during RP. Infrared thermographs were obtained using thermal field measurements to determine the temperature distribution. A numerical analysis of a lightweight ribbed ergonomic artifact is presented to illustrate the VCDT. Moreover, manufacturability was verified based on a thermal-solid coupled finite element analysis. The physical experiment and practice proved that the proposed VCDT provided a robust design paradigm for a layered RP between the steady balance of electrothermal regulation and manufacturing efficacy under hybrid uncertainties.
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