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Research Papers

A Direct Tool Path Planning Algorithm for Line Scanning Based Stereolithography

[+] Author and Article Information
Chi Zhou

Department of Industrial
and Systems Engineering,
University at Buffalo,
The State University of New York,
Buffalo, NY 14260
e-mail: chizhou@buffalo.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received April 22, 2014; final manuscript received September 3, 2014; published online October 24, 2014. Assoc. Editor: Darrell Wallace.

J. Manuf. Sci. Eng 136(6), 061023 (Oct 24, 2014) (10 pages) Paper No: MANU-14-1246; doi: 10.1115/1.4028518 History: Received April 22, 2014; Revised September 03, 2014

This paper presents a novel tool path planning approach for polygonal mirror scanning based stereolithography (STL) process. Compared with traditional laser scanning and mask projection based STL process, the polygonal mirror scanning based process can build part with high surface quality and precision without losing the fabrication efficiency. As an emerging additive manufacturing (AM) process, no efficient tool path planning algorithm is available in current system. This paper presents a direct tool path planning algorithm without converting the three-dimensional model into two-dimensional contours. Different test cases are used to verify its efficiency and effectiveness. Compared with the commercial software, the proposed algorithm is several times faster. Physical parts are also built using the tool path generated by the proposed algorithm.

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Figures

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Fig. 1

Different configurations for photopolymerization based process

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Fig. 2

Line scanning based STL process [11]

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Fig. 3

Building area for line scanning system

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Fig. 4

Framework for line scanning system

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Fig. 5

Slicing and path planning for line scanning based SLA

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Fig. 6

Toggling point calculation for line scanning based SLA

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Fig. 7

Path generation based on even-odd fill rule

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Fig. 8

Direct tool path planning algorithm for hearing aid model

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Fig. 9

Hearing aid model with support structure

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Fig. 10

Line segment calculation for support structure

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Fig. 11

Support widening by offsetting line segment

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Fig. 12

Path planning for one widening line segment

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Fig. 13

Path planning for support structure: (a) line segments of the layer, (b) offset line segments, (c) intersection points after union operation, and (d) tool path for the support structure

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Fig. 14

Clean up the redundant toggling points by union operation

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Fig. 15

Teeth model: (a) original 3D model, (b) toggling points for all the scanning lines, and (c) tool path of a typical layer for the part, and (d) tool path of a typical layer for the support

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Fig. 16

Hand model: (a) original 3D model, (b) toggling points for all the scanning lines, and (c) tool path of a typical layer

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Fig. 17

Head model: (a) original 3D model, (b) toggling points for all the scanning lines, and (c) tool path of a typical layer

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Fig. 18

Fabricated parts for hearing aid model and teeth model using the tool path generated by the proposed approach

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