3D CAD Data Research Articles

Extending Interactive Electronic Maintenance Manual with Web3D Technologies

Rapid developments in Information and Communication Technology have revealed a number of opportunities for supporting a complete product life cycle of the mechanical facilities particularly for maintenance purposes. The complexity of mechanical procedures as well as their perceptions has challenged engineers to create more effective and interactive maintenance manual. Therefore, this paper proposes an advanced electronic maintenance manual with the interactive 3D visualization by using the latest Web3D technologies. The advantage of this method is the visual and three dimensional explanations delivered in the maintenance manuals. This method will extend the traditional work instructions into an interactive electronic maintenance manual. The manual module which involves Cortona3D software is processed by preparation of 3D CAD data format from mechanical facilities. Then this process continues with the addition 3D animation with related texts through the maintenance operations, and converting the modified 3D data into VRML format which enables accessible through Web. The result is an interactive and on-demand electronic maintenance manual which allows users to communicate maintenance problems. The assessment concludes that the 3D maintenance manual will improve an intuitive interface and information retention, encourage visual knowledge and minimize ambiguity .

Role of CT and MRI in the design and development of orthopaedic model using additive manufacturing

ObjectiveTo study the role of Computed tomography (CT) and Magnetic resonance imaging (MRI) for design and development of orthopaedic model using additive manufacturing (AM) technologies. MethodsA significant number of research papers in this area are studied to provide the direction of development along with the future scope. ResultsBriefly discussed various steps used to create a 3D model by Additive Manufacturing using CT and MRI scan. These scanning technologies are used to produce medical as well as orthopaedic implants by using AM technologies. The images so produced are exported in different software like OsiriX Imaging Software, 3D slicer, Mimics, Magics, 3D doctor and InVesalius to produce a 3D digital model. Various criteria's achieved by CT and MRI scan for design and development of orthopaedic implant using additive manufacturing are also discussed briefly. AM model created by this process show exact shape, size, dimensions, textures, colour and features. ConclusionAM technologies help to convert the digital model into a 3D physical object, thereby improving the understanding of patient anatomy for treatment as well as for educational purpose. These scanning technologies have various applications to enhance the AM in the field of orthopaedic. In orthopaedic every patient model is a customised unit, sourced from the individual patient. 3D CAD data captured by these scanning technologies are directly exported in standard triangulate language (STL) format for printing by AM technologies. Crossestion of the physical model fabricated by this process shows a patient's anatomy if the model prepared by using the bone-like material.

“In vitro” Implantation Technique Based on 3D Printed Prosthetic Prototypes

In this paper, Rapid Prototyping ZCorp 310 system, based on high-performance composite powder and on resin-high strength infiltration system and three-dimensional printing as a manufacturing method are used to obtain physical prototypes of orthopaedic implants and prototypes of complex functional prosthetic systems directly from the 3D CAD data. These prototypes are useful for in vitro experimental tests and measurements to optimize and obtain final physical prototypes. Using a new elbow prosthesis model prototype obtained by 3D printing, the surgical technique of implantation is established. Surgical implantation was performed on male corpse elbow joint.

Corrosion Monitoring and Inhibition of Buried Pipes in a Nuclear Power Plant Using a FEM Method or Mixed Inhibitors

Several kinds of pipes in a nuclear power plant were buried in the soil. In order to control the corrosion problems, cathodic protection has been applied to protect the corrosion process in the outer surface of pipes and several corrosion inhibitors have been used to minimize the corrosion in the inner surface of the pipes. This work focused on the corrosion monitoring of the outside of coal tar-coated pipes buried in a nuclear power plant using a FEM method and the corrosion inhibition of the inside of the pipes using mixed inhibitors. The pipes buried in a nuclear power plant were ductile cast iron and these have been suffered under very high cathodic protection condition beyond the appropriate condition. However, cathodic potential measured in the site reveals the non-protected status. Converting from 3D CAD data of the power plant to appropriate type for a FEM simulation was performed and cathodic potential under the applied voltage and current was calculated using the primary and secondary current distribution physics conditions. FEM simulation for coal tar-coated pipe without defects showed the over-protection condition if the pipes are well-coated. On the other hand, we compared the different inhibition mechanisms of organic inhibitor with that of anodic inhibitor. When ethanolamines or nitrite or molybdate were added separately to tap water for inhibiting the corrosion of ductile cast iron, large amounts of inhibitor were needed. However, when mixed inhibitors were added, their amounts were greatly reduced and we found the synergistic effect and also proposed the new mechanism.

Comparison of point cloud data and 3D CAD data for on-site dimensional inspection of industrial plant piping systems

Inspection is vital in industrial plant construction and management. However, traditional inspection methods that rely on human involvement and paper documentation are becoming untenable as modern industrial plants are becoming larger and more complex than legacy facilities. Hence, an efficient and robust method is required to support the inspection of modern industrial plants. In this paper, an improved technique relying on terrestrial laser scanning (TLS) for data acquisition and normal-based region growing and efficient random sample consensus (RANSAC) for point cloud data processing is proposed for the on-site dimensional inspection of the piping systems of an industrial plant. Consequently, the as-built condition of the plant is assessed via a distance-based deviation analysis and a comparison of geometric parameters between the as-designed and as-built models. The method is validated using a dataset acquired from a compartment of a ship has verified the robustness and reliability of the proposed approach.

3D free forms in c-Si via grayscale lithography and RIE

A grayscale technology process for structuring of true 3D shapes into crystalline silicon (c-Si) has been developed. The process combines maskless grayscale lithography and an optimized RIE process. To achieve a 1:1 transfer of the 3D photoresist patterns into c-Si, the RIE process was optimized for a selectivity of S=1 and an anisotropy Af close to one. Suitable process conditions of the RIE process are defined by SF6 flowrate of 3sccm, CHF3 flowrate of 35sccm, a RF power of 100W, a temperature of 10°C and a pressure of 10mTorr. The 3D pattern transfer is demonstrated at special test structures as well as at real 3D structures such as pyramids. The developed process allows a direct transfer from 3D CAD data via maskless grayscale lithography using Heidelberg Instrument DWL66FS to c-Si 3D structures. The pattern transfer accuracy is about 5% in respect to the 3D CAD data.

Development of an AR based method for augmentation of 3D CAD data onto a real ship block image

This paper proposes a method for augmenting a 3D CAD model of a ship block onto an image using an augmented reality technique. A two-dimensional image that captures a ship block is obtained using a digital camera. The image is processed to extract a feature of the block for establishing the correspondence between the block in the image and the 3D CAD model. In this work, a rectangular planar region is used as the feature in the image, which is then compared with face components in the CAD model. Once the correspondence is found, the initial pose of the block is computed using the correspondence information, and the CAD model is then augmented onto the image using the initial pose. Next, a registration process is employed to reduce the registration error further using a Lie Algebra-based method, which iteratively approximates the correct pose while reducing the error. As an option, a manual procedure is provided to allow a user to select the corresponding face for initial pose estimation. Real examples are used for testing the proposed method.

Leveraging 3D geometric knowledge in the product lifecycle based on industrial standards

AbstractWith their practical introduction by the 1970s, virtual product data have emerged to a primary technical source of intelligence in manufacturing. Modern organization have since then deployed and continuously improved strategies, methods and tools to feed the individual needs of their business domains, multidisciplinary teams, and supply chain, mastering the growing complexity of virtual product development. As far as product data are concerned, data exchange, 3D visualization, and communication are crucial processes for reusing manufacturing intelligence across lifecycle stages. Research and industry have developed several CAD interoperability, and visualization formats to uphold these product development strategies. Most of them, however, have not yet provided sufficient integration capabilities required for current digital transformation needs, mainly due to their lack of versatility in the multi-domains of the product lifecycle and primary focus on individual product descriptions.This paper analyses the methods and tools used in virtual product development to leverage 3D CAD data in the entire life cycle based on industrial standards. It presents a set of versatile concepts for mastering exchange, aware and unaware visualization and collaboration from single technical packages fit purposely for various domains and disciplines. It introduces a 3D master document utilizing PDF techniques, which fulfills requirements for electronic discovery and enables multi-domain collaboration and long-term data retention for the digital enterprise.Highlights With their practical introduction by the 1970s, virtual product data have emerged to a primary technical source of intelligence in manufacturing. Modern organization have since then deployed and continuously improved strategies, methods and tools to feed the individual needs of their business domains, multidisciplinary teams, and supply chain, mastering the growing complexity of virtual product development. As far as product data are concerned, data exchange, 3D visualization, and communication are crucial processes for reusing manufacturing intelligence across lifecycle stages. Research and industry have developed several CAD interoperability, and visualization formats to uphold these product development strategies. Most of them, however, have not yet provided sufficient integration capabilities required for current digital transformation needs, mainly due to their lack of versatility in the multi-domains of the product lifecycle and primary focus on individual product descriptions. This paper analyses the methods and tools used in virtual product development to leverage 3D CAD data in the entire life cycle. It presents a set of versatile concepts for mastering exchange, aware and unaware visualization and collaboration from single technical packages fit purposely for various domains and disciplines. It introduces a 3D master document utilizing PDF techniques, which fulfills requirements for electronic discovery and enables multi-domain collaboration and long-term data retention for the digital enterprise. 3D interoperability makes an important contribution to engineering collaboration. Several formats made to that end successively deal with challenges of their time. Some of these such as STEP are highly verbose formats, which gradually encapsulate all information necessary to define a product, its manufacture, and lifecycle support. Others are focusing best on lightweight visualization use cases and endure better with increasing size and complexity of data. Traditional formats like STEP and JT, though, are not capable of supporting the publishing activity in even broader fashion. New tendencies therefore are aiming at strengthening these individual formats through combination with complementary standards or by using document-based approaches. Unlike STEP or JT, 3D PDF can serve multiple purposes and leverages 3D data downstream throughout the product lifecycle to create, distribute and manage ubiquitous, highly consumable, role-specific rich renditions. Based on its container structure, 3D PDF is a fundamentally different approach from traditional experience established in product development – it is an exceptionally proficient contextual aggregation of multi-domain and multi-disciplinary product data. The manufacturing community should embrace it as an addition and great improvement to current engineering collaboration standards. All engineering components required for its descriptions are meanwhile published international standards. The productive use of 3D PDF for sure requires a change in the current mode of operation, be it simply because the traditional CAD model promptly demands new technical descriptions. More perspectives, which have not been primary focus of this approach need to be addressed in order to implement the 3D digital master concept of this paper in the industry. For the complete process to work properly, the actual workflows of today's business organizations must succeed a readiness check involving enhanced technical documentation capabilities of the authoring (CAx) applications based on 3D, PLM, and manufacturing workflows as well as new ways for engineering data communication with supply chain partners in the digital enterprise.

Fabrication of mandible fracture plate by indirect additive manufacturing

Bone fracture is a serious skeletal injury due to accidents and fragility of the bones at a certain age. In order to accelerate fracture healing process, fracture bone plate is use to hold the fracture segment for more stability. The purpose of this study is to fabricate mandibular fracture plate by using indirect additive manufacturing methods in order to reduce time taken during bending and shaping the fracture fixation plate that conform to the anatomy of the fractured bone site. The design and analysis of the plates are performed using CATIA and ANSYS software. The 3D-CAD data were sent to an additive manufacturing machine (fused filament fabricated) to generate master pattern using PLA and the mould were fabricated using Plaster of Paris. A melt ZAMAK 3 was poured directly into the moulds, and left it until completely harden. 3point bending test was performed on the prototype plate using universal testing machine. Stress-strain curve shows the graph exhibited a linear relationship of stress-strain up to a strain value of 0.001. Specimens give a maximum yielding stress and then break before the conventional deflection. Since the maximum flexural stress and the breaking stress are far apart with a plateau stating at strain value of 0.003mm/mm in most specimens, the specimen’s failure types are considered plastic failure mode. The average thickness and width are 1.65mm and 2.18mm respectively. The flexural modulus and flexural strength are 189.5GPa and 518.1MPa, respectively.

Fabrication of Patient Specific Genioplasty Surgical Template Using Investment Casting

Additive Manufacturing (AM) is one of the best techniques to fabricate customized medical models. This technique best suited for the medical industry. The surgical template design and dimensions vary from patient to patient, depending on the anatomy of the patient. AM provides flexibility to design a patient specific surgical template using the patient CT scan data. Medical processing software converts DICOM to 3D CAD data. This 3D CAD data is used to design the patient specific surgical template. This surgical template data is then converted into an STL file format to fabricate medical models using AM machines. The initial surgical template is fabricated using FDM machines, which are easily available and this template is used for pre surgical planning. After satisfactory results are obtained in the pre surgical planning, the same STL file is fabricated using a castable resin. The castable resin model is used for preparation of the mould for casting process. This mould is then used to produce the final surgical template with medical grade SS316. The cost of the final metal surgical template is reduced by 30 percent compared to production of same model fabricated using metal AM system. The major advantage of this process is that we obtain a patient specific template in traditional approved way, but at reduced cost.

Manufacturing of Patient specific AM medical models for Complex Surgeries

Additive Manufacturing (AM) is growing rapidly day by day. In AM sector, medical is one of the fastest growing industry. In the initial days the patient anatomy was analyzed using X-rays where only the 2-Dimensional (2D) representation is made. Later the improvements resulted in the 3D image acquisition with the help of Computed Tomography (CT) scanners, where the data is stored in Digital imaging and communication in medicine (DICOM) images. These DICOM images were used as the source for medical software's to from 3D CAD data. This 3D data is used for virtual simulation and for planning in case of some surgeries. The latest advancement in this is the creation of patient specific physical models. These models contain almost exact replication of the patient anatomy. The surgeon can pre plan the surgery in advance and explore important information before operating the patient's body. In the current work the procedure, advantages and limitations of the medical models along with the case study were discussed.

3D-CADデータと非接触測定点群データの照合技術

3D-CADデータと非接触測定点群データの照合技術

The Effect of Surface Finish on Sculptured Shape Utilizing Scanned Data – Reversed Engineering (CATIA V5 & DELCAM)

The ultimate aim of this study was to investigate the effect of surface finish for a machined part which was programmed by two popular CAD/CAM software namely Catia V5 and Delcam using scanned data obtained from one of the Reverse Engineering methods namely Three-Dimensional (3D) scanning process. A gaming mouse was chosen as the physical part to be scanned and machined because of its sculptured shape and wavy looks. In this study, simultaneous three-axis machining programs were created and machined using three-axis Computer Numerical Control (CNC) Milling machine. Initially, the physical gaming mouse gone through the first process called scanning process using a 3D scanner; model 700 CX in order to capture the 3D CAD data in points cloud form. The raw scanning data then gone through editing process to obtain better surfaces. Moreover, the stable and edited CAD model then undergone CAD/CAM programming process for both mentioned software respectively. There were ten random points chosen to be analyzed for the surface roughness analysis. The arithmetic mean value (Ra) was used as the roughness value reference. The results reveal that the average surface roughness for the ten points was 0.232 μm for Catia V5 whilst for Delcam was around 0.274 μm. Ultimately, Catia V5 producing better surface finish compared to Delcam software concluded from the analysis carried out as presented in this paper.

An investigation on the surface finish of sculptured surface utilizing reverse engineering data of crank case cover – (CATIA V5 & DELCAM)

The ultimate aim of this study was to investigate the effect of surface finish for a machined part which was programmed by two popular Computer Aided Design / Computer Aided Manufacturing (CAD/CAM) software namely as Catia V5 and Delcam (Delcam for Solidworks - DFS) by using scanned data obtained from one of the Reverse Engineering methods namely Three-Dimensional (3D) scanning process. A crank case cover was chosen as the physical part to be scanned and machined because of its sculptured shape and complex geometry. In this study, simultaneous three-axis machining programs were created and machined using threeaxis Computer Numerical Control (CNC) Milling machine; DMC 635 Ecoline. Furthermore, all machining parameters are remained the same for both programs. Initially, the physical crank case cover gone through the first process called scanning process using a 3D scanner; model 700 CX in order to capture the 3D CAD data in points cloud form. The raw scanned data then gone through editing process to obtain better surfaces using Geomagic Studio software. Moreover, the stable and edited CAD model then undergone CAD/CAM programming process for both mentioned software respectively. On the other hand, there were seven random points chosen to be analyzed for the surface roughness analysis. The arithmetic mean value (Ra) was used as the roughness value reference using Mitutoyo Surface Tester. Ultimately, it could be concluded that Catia V5 producing better surface finish compared to Delcam software concluded from the analysis carried out as presented in this paper.

Hot isostatic pressing of IN718 components manufactured by selective laser melting

Selective laser melting and other additive manufacturing (AM) techniques have recently attracted substantial interest of both researchers and the processing industry. The freedom of design leads to completely new possibilities for constructions and, thus, to entirely new products. In the selective laser melting (SLM) process, the components are produced layer-wise using a laser beam. SLM is a powder bed based AM process and is characterized by the complete melting of the utilized powder material. Employing SLM, complex three-dimensional parts and light weight structures can be produced directly from 3D CAD data. However, although SLM is a very promising technology, there are still challenges to solve. In the present study, a close look is taken at the porosity. Under cyclic loading, pores can act as stress raisers and lead to premature crack initiations, which reduce the fatigue strength of the material. Hot isostatic pressing (HIP) offers the possibility to reduce the porosity. HIP combines high pressure and high temperature to produce materials with superior properties. The influence of the HIP process parameters on the density and microstructure of IN718 SLM components is investigated by means of micro X-ray computed tomography and scanning electron microscopy. The results of the experiments show that the majority of pores can be densified by means of HIP. On the other hand, some pores cannot be densified. The reason for this is seen in entrapped argon gas from the SLM process.

Microstructure and mechanical properties of stainless steel/calcium silicate composites manufactured by selective laser melting

Selective laser melting (SLM) is raised as one kind of additive manufacturing (AM) which is based on the discrete-stacking concept. This technique can fabricate advanced composites with desirable properties directly from 3D CAD data. In this research, 316L stainless steel (316L SS) and different fractions of calcium silicate (CaSiO3) composites (weight fractions of calcium silicate are 0%, 5%,10% and 15%, respectively) were prepared by SLM technique with a purpose to develop biomedical metallic materials. The relative density, tensile, microhardness and elastic modulus of the composites were tested, their microstructures and fracture morphologies were observed using optical microscope (OM), scanning electron microscopy (SEM) and X-ray diffraction (XRD). It was found that the addition of CaSiO3 particles influenced the microstructure and mechanical properties of specimens significantly. The CaSiO3 precipitates from the overlap of adjacent tracks and became the origin of the defects. The tensile strength of specimens range 320–722MPa. The microhardness and elastic modulus are around 250HV and 215GPa respectively. These composites were ductile materials and the fracture mode of the composites was mixed mode of ductile and brittle fracture. The 316L SS/CaSiO3 composites can be a potential biomedical metallic materials in the medical field.

Improvement of Surface Finish by Multiple Piezoelectric Transducers in Fused Deposition Modelling

Additive Manufacturing (AM) which embrace as a new range technology of creating and producing end user parts in term of adding material layer by layer to create solid object from 3D CAD data. AM in particular Fused Deposition Modelling (FDM) used (ABS) thermoplastic have shown the most popular among the industry as its technology can print complex geometrical part without human intervention and tools. However, FDM fierce enemy whereas the common problem of stair-stepping, which means that seam lines appear between layers and excess material if often left as a residue, cause to lead rough surface and poor quality finish. It is often desirable for an AM model to have aesthetic or functional importance. Hence, reducing layer thickness will generally improve surface roughness but will add to the build time for the model. As an interest investigate the use of ultrasonic for FDM, this experiment will focus on the effect of applying multiple piezoelectric transducer for FDM printer. This paper aims to explore the effect use of multiple piezoelectric with different frequency applied (27, 40, 50 kHz) to improve surface finish quality part printed by FDM whereby an ultrasonic transducer firmly attached onto the platform. Optical microscope with the aid of pro VIS software version 2.90 was used to measure the quality of surface roughness of samples printed with vibration in the above stated frequency. Hence, it was found that 1 piezo with 50 kHz frequency applied to the FDM machine achieved improve surface finish due to less layer thickness defect and finer layer thickness produce.

CAD and AM-fabricated moulds for fast cranio-maxillofacial implants manufacture

Purpose – The purpose of this study is to suggest the joint use of computer-aided design (CAD) and additive manufacturing (AM) technology for the fabrication of custom-made moulds, designed for the manufacture of polymethyl methacrylate (PMMA) implants for cranio-maxillofacial reconstruction to reduce their fabrication time. Even though tailor-made skull prostheses with a high technological level and state-of-the-art materials are available in the market, they are not always accessible to the general population in developing countries. Design/methodology/approach – Computed tomography data were handled to create a three-dimensional (3D) model of the injury of the patient, by reconstructing Digital Imaging and Communications in Medicine (DICOM) images into an Standard Tessellation Language (STL) file that was further used to design the corresponding implant using CAD software. Accordingly, a two-piece core and cavity moulds that replicated the implant geometry was also CAD designed. The 3D-CAD data were sent to an AM machine (fused deposition modelling) and the moulds were fabricated using polycarbonate as thermoplastic material. A reacting mixture to produce PMMA was poured directly into the fabricated moulds, and left to polymerise until cure. Finally, a clear bubble-free case of study PMMA implant was obtained. Findings – The fabrication of CAD-designed moulds with AM, replacing the production of the injury model, resulted in the reduction of the lead-time in the manufacturing of PMMA around 45 per cent. Additionally, the implant showed better fit than the one produced by conventional process. The use of AM moulds for the fabrication of PMMA implants has demonstrated the reduction in lead-time, which potentially can reduce the waiting time for patients. Social implications – Currently, the demand of cranio-maxillofacial implants at only the Hospital General de México “Dr Eduardo Liceaga” (HGM) is 4,000 implants per year, and the average waiting time for each patient is between 5 and 10 weeks, including third-party services’ delays and the time needed to obtain the economical resources by the patient. Public hospitals in Mexico lack manufacturing facilities, so patients have to make use of laboratories abroad and most of the population have no access to them. The implementation of this suggested procedure in public hospitals may improve the accuracy of the implant, increase the number of patients attended per year (up to 83 per cent) and the reduction in waiting time can also reduce mortality and infection rates. Originality/value – The authors of this paper suggest the joint use of CAD and AM technologies to significantly reduce the production time of PMMA implants by producing moulds rather than the injury model, maintaining the general terms and known steps of the process already established for PMMA implants.

Generating a reference model of the surface with a hole for downstream process

ABSTRACTThe value of 3D CAD models is continuously increasing in downstream processes. The more extensive use of a 3D model outside traditional design and manufacturing is trending now. To distribute 3D data quickly to downstream departments is significant boosts to product quality, production costs, and delivery to markets. Unfortunately, interoperability causes poor communication since downstream applications rely on the reusability and interoperability of CAD models. However, 3D CAD data size for expressing precise forms tends to be big and time-consuming for computation, which may interfere in the communication. In addition, downstream processes emphasize surface smoothness more than precision. Therefore, this paper describes the reconstruction method of a smooth surface by integrating the advantages of Gregory and B-spline surfaces. In this paper, a new surface representation is proposed. Two surfaces are connected with G1-continuity by using the control points at the common boundary obtained from jo...

フェムト秒レーザー励起を用いた表面ナノ加工に関する研究

Layer manufacturing technique such as stereolithography is powerful tool to fabricate the 3D shape based on 3D-CAD data. The resolution of the 3D fabrication is limited by the spot size in x and y axis when we use laser to deposit the material by using the laser. As for the resolution in z axis, it is decided by the layer thickness to deposit the material. In the stereolithography by using the laser beam, the material is usually transparent. Thus it is difficult to control the solidification size in z direction, which is the direction of the beam propagation. We suggest a laser surface processing technique is investigated to improve the height resolution of layer manufacturing. In this study, make a challenge to achieve the processing on the surface with processing depth, which is lower than the layer thickness.