Prescriptive Modeling and Compensation of In-Plane Shape Deformation for 3-D Printed Freeform Products

Luan, He; Huang, Qiang

doi:10.1109/tase.2016.2608955

Cited by 39 publications

(10 citation statements)

References 31 publications

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“…In contrast, Huang, Zhang, Sabbaghi, and Dasgupta [12] conceived of a distinct functional modeling framework that effectively accounts for the correlation in deviation between different directions, and decouples geometric shape complexity from deviation modeling and compensation. Further advances and experiments under their framework include in-plane deviation modeling for polygons and free-form shapes [11,16,25], interference modeling for discretized compensation plans [24], and out-of-plane deviation modeling for 3D shapes [14].…”

Section: Introductionmentioning

confidence: 99%

Model transfer across additive manufacturing processes via mean effect equivalence of lurking variables

Sabbaghi¹,

Huang²

2018

Ann. Appl. Stat.

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Shape deviation models constitute an important component in quality control for additive manufacturing (AM) systems. However, specified models have a limited scope of application across the vast spectrum of processes in a system that are characterized by different settings of process variables, including lurking variables. We develop a new effect equivalence framework and Bayesian method that enables deviation model transfer across processes in an AM system with limited experimental runs. Model transfer is performed via inference on the equivalent effects of lurking variables in terms of an observed factor whose effect has been modeled under a previously learned process. Studies on stereolithography illustrate the ability of our framework to broaden both the scope of deviation models and the comprehensive understanding of AM systems.

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Section: Introductionmentioning

confidence: 99%

Model transfer across additive manufacturing processes via mean effect equivalence of lurking variables

Sabbaghi¹,

Huang²

2018

Ann. Appl. Stat.

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“…Finally, no effort has been conducted to determine if a global form deviation model could be applied, considering local deviations as a function of part location, type of surface, and polar coordinates in a single model, instead of using independent models for each combination of significant factors. This possibility could lead to a general compensation model, in the direction pointed out by previous works [ 32 , 33 ]. Although this idea falls out of the scope of present research, it is believed to be worthy of further research.…”

Section: Application Examplementioning

confidence: 89%

“…Tong et al [ 28 ] described form errors in material extrusion (MEX) processes as a function of 18 parametric errors and elaborate compensation models for the STL file, and for individual slices, achieving clear improvements on part geometry. The group of Professor Huang has done extensive research in shape deviation modelling and compensation [ 29 , 30 , 31 , 32 , 33 , 34 , 35 , 36 ]. They proposed a polar deviation model, especially suited for cylindrical surfaces, where the deviations between the actual surface and the nominal one were evaluated in the normal direction to each surface point [ 29 ].…”

Section: Introductionmentioning

confidence: 99%

“…The model was extended to a system-level approach to predict and compensate generic shapes [ 30 ] and used to evaluate the effect of a discrete compensation using a finite number of levels [ 31 ]. Their model has been also extended to generalized shapes [ 32 ] and previously untried shapes [ 33 ] to create a global deviation modelling strategy. Additionally, they have made attempts to extend 2D compensation to 3D compensation by dividing the problem into in-plane deformation (concerning the cross-section) and out-of-plane deformation [ 35 , 36 ].…”

Section: Introductionmentioning

confidence: 99%

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A Design for Additive Manufacturing Strategy for Dimensional and Geometrical Quality Improvement of PolyJet-Manufactured Glossy Cylindrical Features

Beltrán¹,

Álvarez²,

Blanco³

et al. 2021

Polymers

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The dimensional and geometrical quality of additively manufactured parts must be increased to match industrial requirements before they can be incorporated to mass production. Such an objective has a great relevance in the case of features of linear size that are affected by dimensional or geometrical tolerances. This work proposes a design for additive manufacturing strategy that uses the re-parameterization of part design to minimize shape deviations from cylindrical geometries. An analysis of shape deviations in the frequency domain is used to define a re-parameterization strategy, imposing a bi-univocal correspondence between verification parameters and design parameters. Then, the significance of variations in the process and design factors upon part quality is analyzed using design of experiments to determine the appropriate extension for modelling form deviation. Finally, local deviations are mapped for design parameters, and a new part design including local compensations is obtained. This strategy has been evaluated upon glossy surfaces manufactured in a Vero™ material by polymer jetting. The results of the proposed example showed a relevant improvement in dimensional quality, as well as a reduction of geometrical deviations, outperforming the results obtained with a conventional scaling compensation.

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“…Nowadays, 3-D printing techniques are widely used in manufacturing automation (see [17], [24], and [25]). In our work, we pay attention to a DLP-based 3-D printing called MIP-based stereolithograhy (MIP-SLA) [20], [21], which follows the SLA technique but replace the point or line light sources with an areal light source.…”

Section: Related Workmentioning

confidence: 99%

Delta DLP 3-D Printing of Large Models

Liu

et al. 2018

IEEE Trans. Automat. Sci. Eng.

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This paper presents a 3-D printing system that uses a low-cost off-the-shelf consumer projector to fabricate large models. Compared with traditional digital light processing (DLP) 3-D printers using a single vertical carriage, the platform of our DLP 3-D printer using delta mechanism can also move horizontally in the plane. We show that this system can print 3-D models much larger than traditional DLP 3-D printers. The major challenge to realize 3-D printing of large models in our system comes from how to cover a planar polygonal domain by a minimum number of rectangles with fixed size, which is NP-hard. We propose a simple yet efficient approximation algorithm to solve this problem. The key idea is to segment a polygonal domain using its medial axis and afterward merge small parts in the segmentation. Given an arbitrary polygon with n generators (i.e., line segments and reflex vertices in), we show that the time complexity of our algorithm is O(n 2 log 2 n) and the number of output rectangles covering is O(K n), where K is an input-polygon-dependent constant. A physical prototype system is built and several large 3-D models with complex geometric structures have been printed as examples to demonstrate the effectiveness of our approach. Note to Practitioners-Low-cost 3-D printers and 3-D printing of large models are two important but often conflicting goals in manufacturing industry. Usually low-cost devices such as DLP 3-D printer using an off-the-shelf consumer projector cannot print large models, due to the small projection area of the projector. In this paper, we propose to horizontally move the platform such that a large area can be printed by the composition of multiple small projection areas. Based on this new mechanism, we propose a simple yet efficient algorithm to cover an arbitrary polygonal shape (possibly with holes or multiple disjoint poly-Manuscript

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Prescriptive Modeling and Compensation of In-Plane Shape Deformation for 3-D Printed Freeform Products

Cited by 39 publications

References 31 publications

Model transfer across additive manufacturing processes via mean effect equivalence of lurking variables

Model transfer across additive manufacturing processes via mean effect equivalence of lurking variables

A Design for Additive Manufacturing Strategy for Dimensional and Geometrical Quality Improvement of PolyJet-Manufactured Glossy Cylindrical Features

Delta DLP 3-D Printing of Large Models

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