Layered Manufacturing from Multi-Level Models

For layered manufacturing, a 3D CAD model has to be converted from a solid representation to a 2D layered cross section. The process usually involves face triangulation or meshing of a sculptured object and then extraction of cross sections from the meshed models. In current systems, the resulting model suffers from topological problems such as degenerate facets, undesired holes or flipped normals that cause uncompleted cross sections that cannot be manufactured as layers. Therefore, time consuming processes for facet repair were added to these CAD systems.

This work proposes a new method for extracting the cross-sections and overcoming the topological problems. In this method, a mesh is reconstructed from the 3D model and represented in multi-level hierarchical structure. The proposed method utilizes the hierarchical model by extracting the cross-sections in real time based on the incremental marching cube algorithm. Moreover, during construction, the method checks the topology and creates a complete cross section that can be manufactured in layers. The method is applied to multi-level models so that a layered part can be constructed in any desired Level Of Detail (LOD), with rough or fine layers according to the application requirements. Several examples  of multi-level models for layered manufacturing of any desired Level Of Detail (LOD), with rough or fine layers according to the application requirements  will be demonstrated.

Keywords:  Layered manufacturing, LOD models, cross sections.
 

Layers extracted from low resolution picture.	Layers extracted from high resolution picture.