Data Processing for Additive Manufacturing

Technology: CAD model preparation

 DATA PROCESSING FOR ADDITIVE MANUFACTURING TECHNOLOGY

It is necessary to "translate" the representation of the model in that Software into something more
"universal" that the AM equipment software can understand. This translation process of CAD model is considered
as data processing.

Standardized computer exchange files known as interface standards have been developed. Interface
standard is the vital link between the computer aided design (CAD) modeling and AM equipment.

In general, from the 3D-CAD Software, we need to export the model as interface standards.
 Data Formats for the AM Process
Additive manufacturing systems require that the files of 3D-CAD digital models be exported in
the proper formats called interface standards. The most popular interface standards include:
1. Standard Tessellation Language (STL)
2. Initial Graphics Exchange Specification (IGES)
3. Standard for The Exchange Of Product model data (STEP)
4. Hewlett Packard Graphics Language (HPGL)
5. Computerized Tomography (CT)
6. Rapid Prototyping Interface (RPI)
7. Common Layer Interface (CLI)
8. Layer Exchange ASCII Format (LEAF)
9. Surface Triangles Hinted formats (STH) , etc
 STL is the most commonly used file format. Because of the application of the STL

format, a vast majority of CAD programs have the possibility of exporting data in

this format.

These programs include:

 AutoCAD,  Rhino,
 Alibre,  Solid Designer,
 CATIA,  SolidEdge
 I-DEAS,  SolidWorks,
 IronCAD,  Think3, NX and
 Mechanical Desktop,  3D Studio Max.
 ProE,
History
• STL file format was developed and published in 1987 by 3D systems for converting 3D CAD models for use in

stereo lithography.

• STL is now a standard output for nearly all solid modeling CAD systems and has also been adopted by AM

system vendors.

• STL is widely believed to be an abbreviation of the word STereoLithography, though sometimes it is also

referred to as ' 'Standard Tessellation Language" or "Standard Triangle Language".

 STL File

 STL file format is a triangular representation of a 3D surface geometry. That means when a CAD model is exported to STL

format, the surface is be subdivided in a triangular mesh.

 The STL files translate the part geometry from a 3D-CAD system to the AM machine (fig, ).

 STL file has the potential for defining any shape with any number of edges.

 It uses triangles or groups of triangles to approximate all surfaces.

 STL file can be in ASCII or in binary format. The ASCII STL format file is larger but legible.

 AM machines need the precise design data as formatted in STL files in order to divide object designs into slices and create

production paths.
STL File Structure

 STL format is composed of only one type of element, a facet. STL file consists of a list of facet data.

 A facet is a small triangle which the surface of object is broken down into. Each triangular facet is described by its

unit normal and three vertices of the facet corners (fig.)

 A unit normal is a perpendicular line to a triangle. The normal and three vertices are specified by three

coordinates (x, y, z) each, so there is a total of twelve numbers stored for each facet.

 The orientation of facets (which way is inside of Objects and which way is outside) is determined by a direction of

unit normal and the order in which the vertices are listed.
 The facets define the surface of a 3D object. Therefore, each facet is a part of the

boundary between the interior and the exterior of the object.

 Since the STL file format is a polyhedral representation of a surface model with triangular

facets, the facets must obey the vertex to vertex rule and facet orientation rule.

 Vertex to vertex rule: STL format has a rule so-called "vertex to vertex rule". This rule is

that each facet must share two vertices with each of its adjacent facets.
Conversion of 3D-CAD Model into STL File

Tessellation of a solid cylindrical CAD model

 The process of converting the 3D-CAD model into the STL format is called tessellation. In tessellation process

three-dimensional model geometry is approximated by means of triangular surfaces (fig.).

 The accuracy of the approximation depends on the model surface shape. The size and shapes of the triangles

can be regulated by setting the proper parameters of data export:

 Flat surfaces are fully mapped by triangles. The mapping of curvilinear surfaces causes the emergence of the

so-called chordal error.

 Chordal Tolerance

The maximum deviation between an original surface of a CAD model and a triangle of

tessellated model is termed as chordal error (figure 2.14).

 The size of triangles depends on the chordal error.

 The error is measured perpendicularly to the triangle surface, and its value depends on the assumed

approximation parameters.

 The error of the chord is also responsible for the accuracy of the construction of convex and concave

surfaces having different radii of curvature.

 The parameters of geometric data export from 3D-CAD systems should be dictated by the assumed

accuracy of mapping the physical model built by the AM device.

 Increasing the surface approximation accuracy in the process of tessellation causes an increase in the

number of triangles describing the model surfaces (fig.) and a greater size of the STL file.
Example of surface tessellation
 Errors in STL File
In some cases, errors may appear in the process of creating triangular facets. There are
four types of flaws that may appear in STL files.
1. First type is inconsistency problem such as incorrect normal vector and inconsistent normal
vector.
2. Second type is malformation problem, for instance cracks and holes that exist in the STL
models.
3. Third type of flaws in STL models is illegal over laps and
4. Final type of flaws in STL models is non-manifold facets.
Flaws those appear in the process of creating triangular facets can be checked and corrected
afterwards.
 Important Consideration to Produce a Good STL File
Following is brief checklist which can help to produce good STI file:
 As a typical example. mesh with triangles approximately the size between 0.02mm (.001") to 0.05 mm (.002") will

produce a good quality STL, file. It has to be kept in mind that, if mesh tolerance further reduced down doesn’t

mean prototype accuracy will be improved.

 Parts with many contoured or curved surfaces need to have fine tolerance than straight geometric parts.

 STL files are always preferred to be saved in Binary format than ASCII mode.

 Generally STL file has no UNITS attached to it so it's always good practice to send overall part sizes along with the

STL file Otherwise it will be difficult to know the part dimensions. Most common units are "mm" or "inches".
 Some CAD systems will generate error messages during STL conversion showing that some part geometry is outside of

the positive X, Y, Z quadrant or is in negative space. These warning messages can be ignored.

 Make sure to join all the solid model pieces to single entity which is needed to see in a single prototype. Otherwise all

those bits & pieces will end up separately in STL file and time has to be spend to join them together, unless you want

them to be separately made.

 Paying attention to these critical aspects before exporting to STL is very important since once the 3D CAD model is

converted to the new format it cannot be changed or modified anymore. This is also why it is highly recommended to

save a copy of the file and the STL separately: