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研究生(外文):Yi-Cheng Chang
論文名稱(外文):The Development of Adaptive 3-D Geometric Model Slicing for Rapid Prototyping Systems
指導教授(外文):Ren C. Luo
外文關鍵詞:Rapid PrototypingAdaptive Slicing
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In recent years, Rapid Prototyping technology is known as one of the efficient procedures to improve product design so as to reduce design cycle and product costs. Slicing is an important process in whole Rapid Prototyping. It decomposes the three-dimensional computer-aided design (CAD) model into two-dimensional layer contours that can be easily built in a single deposition. The slicing method affects accuracy and the time of building the parts that are established by rapid prototyping system. In general, commercial rapid prototyping systems use traditional slicing method which slices the model in uniform layer thickness so that operators must compromise between model with fast fabrication as well as low accuracy, and slow fabrication with high accuracy by choosing thick or thin building layers. Thus, adaptive slicing needs to be performed with a view to control the accuracy of the model and to reduce the staircase effect.
The thesis is divided into two parts. In the first place, the focus of this thesis is to develop a new adaptive slicing algorithm. Based on the proposed method, the three-dimensional CAD model can be sliced into variable layer thickness automatically by detecting the change of the geometry curvature in the vertical direction of the CAD model. According to the computational slicing results, the proposed algorithm can reduce larger number of layers than uniform slicing method without reducing the model accuracy. Besides, it takes less time to slice than the ordinary slicing method. Secondly, the aim is to reform the Photo-Mask Shaping (PMS) rapid prototyping system that is developed by our research group. This research serves to improve the system architecture and the manufacturing process of the PMS rapid prototyping system so that this system can build the parts with speed and accuracy. Finally, the proposed slicing method is implemented on the PMS rapid prototyping system with efficiency.

摘 要i
Table of Contentsiv
List of Figuresvii
List of Tablesx
Chapter 1 : Introduction1
1.1 Rapid Prototyping Processes3
1.2 Slicing for Rapid Prototyping5
1.3 Staircase Effect of Rapid Prototyping7
1.4 Objectives and Organization of Thesis Research8
1.4.1 Problem Statement8
1.4.2 Solution Overview8
1.4.3 Thesis Organization9
Chapter 2 : Literature Review11
2.1 Classification of Rapid Prototyping Technologies11
2.1.1 Liquid Based12
Stereolithography Apparatus (SLA)12
Solid Ground Curing (SGC)14
2.1.2 Powder Based16
Selective Laser Sintering (SLS)17
Ballistic Particle Manufacturing (BPM)19
2.1.3 Solid Based21
Fused Deposition Modeling (FDM)21
Multi-Jet Modeling System (MJM)23
Model Maker (MM)24
Laminated Object Manufacturing (LOM)26
2.2 STL File Format28
2.3 Adaptive Slicing29
Chapter 3 : Related Mathematical Concepts38
3.1 Basic Geometric Concepts38
3.1.1 Edge-Line Intersections39
3.1.2 Rotation in Space41
3.1.3 Projection of Geometric Model43
Perspective Projections44
Orthogonal Projections46
3.2 Winding Rules48
Even-odd rule48
Non-zero winding rule48
3.3 Regression Analysis49
3.3.1 The linear regression model49
3.3.2 Ordinary least squares estimation50
3.3.3 Assumptions for regression analysis51
3.3.4 Properties of the OLS estimator53
Chapter 4 : Adaptive Slicing Algorithm55
4.1 Pre-processes56
4.1.1 Loading Data Before Slicing56
4.1.2 Data Sorting58
4.2 Pre-slicing (Thick Layer Generation)60
4.2.1 Determining Thick Layer Thickness60
4.2.2 Horizontal Surface Detection63
4.3 Contour Generation64
4.3.1 Contour Orientation Convention64
4.3.2 Composing The Contour64
4.3.3 Multi-Contours in a Layer69
4.4 Generating Variable Layer Thickness70
4.5 Photo-mask Generation74
Chapter 5 : Photo-mask Shaping Rapid Prototyping System76
5.1 System Structure77
5.1.1 Data Processing78
5.1.2 Photo-Mask80
5.1.3 Curing Light Source81
5.1.4 Remote Control and Monitoring Unit85
5.1.5 Z-axis Elevator86
5.2 Experimental Setup88
Chapter 6 : Experimental Results92
6.1 Software Results92
Case 1: Slicing Result by Using Various Slicing Methods93
Case 2: Slicing Result by Using Various Slicing Methods95
Case 3: Slicing Result by Using Various Slicing Methods96
6.2 Experimental Results for The Improved RP System99
Case 4: RP Part Built by PMS RP System100
Case 5: RP Part Built by PMS RP System103
Case 6: RP Part Built by PMS RP System103
Chapter 7 Conclsion and Discussion105
Chapter 8 Contribution107
Appendix A The Family Tree of Rapid Prototyping113
Liquids Based113
Powders Based115
Solid Materials Based116
Sheets Based117
Gas, Atoms and Other Odd Stuff Based118

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