Volume deviation in direct slicing

Abstract

Purpose

To calculate the volume deviation between a CAD model and built‐up part in 5‐axis laminated object manufacturing employing direct slicing with first‐order approximation.

Design/methodology/approach

It is proposed here that the deviation between the CAD model and the built‐up part, which is normally calculated as a linear dimension in specific 2D sections of the CAD model, be treated as a volume (as it actually is), for higher accuracy in subsequent calculations. An algorithm has been developed and implemented for identification and calculation of volume deviation, considering all possibilities.

Findings

It has been conclusively shown that volume deviation consideration results in improved feature recognition and less approximation.

Research limitations/implications

Increase in complexity of the CAD model leads to a considerable increase in the volume deviation computation time. Future research in this area would focus on optimization and calculation of the slice heights based on volume deviation.

Practical implications

Calculation of volume deviation would help eliminate the loss of intricate features in a complex surface and thus improve feature recognition. Slice height calculations based on volume deviation would reduce the deviation between the actual model and the built‐up part.

Originality/value

A new method has been developed for the calculation of volume deviation that could be implemented in the rapid prototyping software packages so as to build prototypes with higher accuracy.

Citation

Kumar, C. and Roy Choudhury, A. (2005), "Volume deviation in direct slicing", Rapid Prototyping Journal, Vol. 11 No. 3, pp. 174-184. https://doi.org/10.1108/13552540510601309