Adaptive ruled layers approximation of STL models and multiaxis machining applications for rapid prototyping

Abstract

This paper presents a new method of generating adaptive ruled layers for rapid prototyping (RP) processing of complex parts. To increase the accuracy and reduce the build time, an adaptive ruled layer approximation of the stereolithography (STL) models and multiaxis path planning for rapid prototyping are proposed. In this paper, a new method of constructing ruled layers from slicing STL points is developed to approximate the STL models with better surface accuracy. A technique of surface error analysis is presented to find the maximum errors at different layers of RP parts. By finding the RP surface errors, adaptive ruled layers are generated for the RP process of the STL CAD models. Using the constructed ruled layers of the STL models, the multiaxis material removal process is integrated with traditional RP processes to achieve better surface accuracy and to reduce the total RP build time. Computer implementation and illustrative examples are presented.