Mechanical Engineering, Virginia Polytechnic Institute and State University
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.