Adaptive high-precision exterior, high-speed interior, layered manufacturing

Abstract

Contemporary layered manufacturing systems build parts using a constant layer thickness. Such systems must seek a compromise between fast fabrication and large inaccuracies on the one hand, and slow fabrication and high precision on the other. This thesis demonstrates how this compromise can be avoided. Specifically, it segregates solid models described in the STL file format into exterior and interior regions. The exterior regions are fabricated with thin, dense, adaptive thickness layers, using narrow material deposition, to ensure high-precision part surfaces. Concurrently, the interior regions are fabricated with thick, sparse layers, using wide material deposition, to maximize build speed and minimize material usage. Experimental software has been developed and sample parts have been fabricated to demonstrate proof of concept.