Predictive modeling of in-plane geometric deviation for 3D printed freeform products
01 Aug 2015-pp 912-917
TL;DR: This work makes a breakthrough by directly predicting arbitrary freeform shape deviations from CAD design by establishing a general model predicting the in-plane (x-y plane) geometric deviations of AM built freeform products.
Abstract: Although 3D printing or additive manufacturing (AM) holds great promise as a direct manufacturing technology, the dimensional geometric accuracy remains a critical issue, especially for freeform products with complex geometric shapes Efforts have long been attempted to improve the accuracy of AM built freeform products But there is a lack of generic methodology transparent to specific AM processes This study fills the gap by establishing a general model predicting the in-plane (x-y plane) geometric deviations of AM built freeform products Built upon our previous predictive model and optimal compensation study for cylinder and polyhedron shapes, this work makes a breakthrough by directly predicting arbitrary freeform shape deviations from CAD design Experimental investigation using stereolithography process successfully validates the proposed methodology, which indicates the prospect of optimal compensation for freeform products built by a varieties of AM processes
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01 Aug 2010
TL;DR: Stereolithography is a solid freeform technique (SFF) that was introduced in the late 1980s as discussed by the authors, which has the highest fabrication accuracy and an increasing number of materials that can be processed is becoming available.
Abstract: Stereolithography is a solid freeform technique (SFF) that was introduced in the late 1980s Although many other techniques have been developed since then, stereolithography remains one of the most powerful and versatile of all SFF techniques It has the highest fabrication accuracy and an increasing number of materials that can be processed is becoming available In this paper we discuss the characteristic features of the stereolithography technique and compare it to other SFF techniques The biomedical applications of stereolithography are reviewed, as well as the biodegradable resin materials that have been developed for use with stereolithography Finally, an overview of the application of stereolithography in preparing porous structures for tissue engineering is given
319 citations
TL;DR: Additive manufacturing (AM), commonly known as three-dimensional printing, is widely recognized as a disruptive technology, and it has the potential to fundamentally change the nature of future man as discussed by the authors.
Abstract: Additive manufacturing (AM), commonly known as three-dimensional printing, is widely recognized as a disruptive technology, and it has the potential to fundamentally change the nature of future man
80 citations
TL;DR: This work establishes an analytical foundation of optimal compensation of 3D shape deformation for high-precision AM through compensation of the product design to offset the geometric shape deformed.
Abstract: Additive Manufacturing (AM) or three-dimensional (3D) printing is a promising technology that enables the direct fabrication of products with complex shapes without extra tooling and fixturing. However, control of 3D shape deformation in AM built products has been a challenging issue. One viable approach for accuracy control is through compensation of the product design to offset the geometric shape deformation. This work establishes an analytical foundation of optimal compensation of 3D shape deformation for high-precision AM.
64 citations
TL;DR: The experimental results successfully demonstrate the effectiveness of the proposed three-step strategy to manage multiple error sources in the FDM processes.
Abstract: Additive manufacturing (AM) or 3-D printing refers to a new class of technologies that actively construct products directly from any 3-D digital model. In the future, the broader applications of AM will require a cost reduction of AM machines. Currently, the products fabricated by low-end machines, such as those fabricated using fused deposition modeling (FDM) processes, suffer from the issue of low dimensional accuracy due to multiple error sources. To properly manage error sources for improved prevision, this paper proposes a novel strategy for error compensation in the FDM processes. First, we consecutively attribute the dimensional inaccuracy to two major error sources that affect the geometric shape of the product: 1) positioning error of the extruder and 2) shape deformation induced by processing error, including material phase change and other variations that occur. The extruder positioning error is characterized by a Kriging model, while the modeling of shape deformation due to processing error follows the method developed by Huang et al. Second, using error equivalence concept, we transform the positioning error into the equivalent amount of design input error. Finally, we adjust the design to compensate for the overall shape deviation. To validate this strategy, we conduct a designed experiment for the shape deviation prediction and the compensation. The experimental results successfully demonstrate the effectiveness of the proposed three-step strategy to manage multiple error sources in the FDM processes.
63 citations
Cites background from "Predictive modeling of in-plane geo..."
...As demonstrated in [13] and [23], the predictive model for simple cylindrical shape serves a fundamental basis function to connect and extend to polygons and freeform 2-D shapes....
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TL;DR: A comprehensive literature review on statistical transfer learning is conducted, i.e., transfer learning techniques with a focus on statistical models and statistical methodologies, demonstrating how statistics can be used in transfer learning.
Abstract: The rapid development of information technology, together with advances in sensory and data acquisition techniques, has led to the increasing necessity of handling datasets from multiple domains. In recent years, transfer learning has emerged as an effective framework for tackling related tasks in target domains by transferring previously-acquired knowledge from source domains. Statistical models and methodologies are widely involved in transfer learning and play a critical role, which, however, has not been emphasized in most surveys of transfer learning. In this article, we conduct a comprehensive literature review on statistical transfer learning, i.e., transfer learning techniques with a focus on statistical models and statistical methodologies, demonstrating how statistics can be used in transfer learning. In addition, we highlight opportunities for the use of statistical transfer learning to improve statistical process control and quality control. Several potential future issues in statistic...
45 citations
References
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TL;DR: Stereolithography is a solid freeform technique (SFF) that was introduced in the late 1980s as mentioned in this paper, and it has been widely used in biomedical applications, as well as the biodegradable resin materials developed for use with stereolithography.
1,760 citations
"Predictive modeling of in-plane geo..." refers background in this paper
...This provides great convenience to directly build geometrically complex products without tooling and fixturing costs [2]–[4]....
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753 citations
"Predictive modeling of in-plane geo..." refers background in this paper
...Three-dimensional (3D) printing or additive manufacturing (AM) holds great promise as a direct manufacturing technology [1]....
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01 Jan 1997
401 citations
"Predictive modeling of in-plane geo..." refers methods in this paper
...Research on solid freeform fabrication (SFF) [12] have been focusing more on design, process planning, finite element 978-1-4673-8183-3/15/$31.00 ©2015 IEEE 912 modeling (FEM), materials, processes, and machines....
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...Research on solid freeform fabrication (SFF) [12] have been focusing more on design, process planning, finite element 2015 IEEE International Conference on Automation Science and Engineering (CASE) Aug 24-28, 2015....
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TL;DR: An efficient algorithm is proposed to find M points, among those given, which define a polygonal curve that is a globally optimal approximation to the given points.
234 citations
Additional excerpts
...optimized polygon to approximate a freeform [15]....
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TL;DR: In this paper, the authors developed a new approach to predict part shrinkage and derive an optimal shrinkage compensation plan to achieve dimensional accuracy in direct 3D printing, which was demonstrated both analytically and experimentally in a stereolithography process.
Abstract: Dimensional accuracy is a key control issue in direct three-dimensional (3D) printing. Part shrinkage due to material phase changes often leads to deviations in the final shape, requiring extra post-machining steps for correction. Shrinkage has traditionally been analyzed through finite element simulation and experimental investigations. Systematic models for accuracy control through shrinkage compensation are rarely available, particularly for complete control of all local features. To fill the gap for direct printing and compensate for shape shrinkage, this article develops a new approach to (i) model and predict part shrinkage and (ii) derive an optimal shrinkage compensation plan to achieve dimensional accuracy. The developed approach is demonstrated both analytically and experimentally in a stereolithography process, one of the most widely employed 3D printing techniques. Experimental results demonstrate the ability of the proposed compensation approach to achieve an improvement of an order of magnit...
158 citations