Title page for ETD etd-2198-105345

Type of Document Master's Thesis
Author Tyberg, Justin
Author's Email Address tyberg@phoenix-int.com
URN etd-2198-105345
Title Local Adaptive Slicing for Layered Manufacturing
Degree Master of Science
Department Mechanical Engineering
Advisory Committee
Advisor Name Title
Bohn, Jan Helge Committee Chair
Kander, Ronald G. Committee Member
Myklebust, Arvid Committee Member
  • adaptive slicing
  • calibration
  • contour matching
  • fuxed deposition modeler
  • FDM
  • rapid prototyping
Date of Defense 1998-02-16
Availability unrestricted
Existing layered manufacturing systems fabricate parts using

a constant build layer thickness. Hence, operators must

compromise between rapid production with large surface

inaccuracies, and slow production with high precision, by

choosing between thick and thin build layers, respectively.

Adaptive layered manufacturing methods alleviate this

decision by automatically adjusting the build layer

thickness to accommodate surface geometry, thereby

potentially enabling part fabrication in significantly less

time. Unfortunately, conventional adaptive layered

manufacturing techniques are often unable to realize this

potential when transitioning from the laboratory to an

industrial setting. The problem is that they apply the

variable build layer thickness uniformly across each

horizontal build plane, applying the same build layer

thickness to all parts and part features across that plane

even though they have different build layer thickness needs.

When this happens, the advantage of using adaptive build

layer thicknesses is lost. This thesis demonstrates how

to minimize fabrication times when implementing adaptive

layered manufacturing. Specifically, it presents a new

method in which each part or individual part feature is

assigned a distinct, independent build layer thickness

according to its particular surface geometry. Additionally,

this thesis presents a calibration procedure for the Fused

Deposition Modeler (FDM) rapid prototyping system that

enables accurate, adaptively sliced parts to be physically

realizable. Experimental software has been developed and

sample parts have been fabricated to demonstrate both

aspects of this work.

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