Chapter 5 - Software interface issues in consideration of additive manufacturing machines and processes

Abstract

The use of solid modeling is widely used in a product development process, but the solid modeling is largely associated with surface generation processes either in the form of sketch and sweep, extrusion process, and feature addition or removal. As a result, every domain space within the model is not conducive to the additive manufacturing (AM) machine interface. Furthermore, for thermoplastics the polymerization process differs from material to material as the degree of polymerization varies, and hence one generic program will not suffice for the entire needs of AM. On a similar note, for the powder-based AM process, melting and fusion or bonding differs from material to material, and inclusion of process dynamics to the software remains a daunting challenge for producing AM components that are compatible to the existing industrial components. In general, the design model files are converted into stereolithography (STL) files with the intention of accommodating every domain space of the component and eliminations of voids, gaps, and overrun. However, the STL files need large corrections to meet the intended objectives. This procedure helps to manufacture a competitive industrial component using the process of AM. Every commercial solid-modeling, computer-aided design system has the ability to output to an AM machine. In this chapter attempts are made to discuss the STL file format with discussions on the most common part-building errors and other value-added software, which assist the STL files to produce AM components with the least defects. The chapter also defines the terms associated with software integration, typical files and corrections required, and how it can be accomplished in consideration of material behavior, machine accuracies, and geometric mismatches.