Curved Layer Slicing based on Isothermal Surface
Yujie Shan, Dongming Gan, Huachao Mao
Abstract
Conventional slicing algorithms for additive manufacturing (AM) processes slice the designed model into a set of planar layers, due to the simplicity, robustness, and generality of most geometries. However, such planar-layer-based slicing significantly limits the performance of the AM system with stair-stepping surface finishing, massive supporting structures, non-conformable to curved substrates, and reduced strength for thin shell structures. To mitigate these drawbacks of planar layer slicing, we presented a curved layer slicing method by utilizing the isothermal surfaces in heat transfer simulation. The designed part is virtually placed on a heated substrate, and the heat spread out through the part, which establishes a temperature field. The isothermal surfaces of this temperature field naturally create curved layers for the printing process. Our method successfully generated curved layers and tool paths for additive manufacturing processes with three-axis and multi-axis 3D printing. A multi-axis motion 3D printing machine is developed based on fused decomposition modeling (FDM). Several test cases were performed to verify and demonstrate our slicing method’s capabilities. A discussion of future development on our general non-planar slicing system was also given.