ADDITIVE MANUFACTURING

University JNTU Kakinada

Regulation R 16
Year IV Year
Semester I Semester
Teaching Classes 3+1
Credits 3
Name of the Faculty Singuru Rajesh
Unit V - Module-1: RP Data formats

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 UNIT-5: Rapid Prototyping Data formats
SYLLABUS

RAPID PROTOTYPING DATA FORMATS:

STL Format, STL File Problems, consequence of building valid and invalid
tessellated models, STL file Repairs: Generic Solution, other Translators, Newly
Proposed Formats.
RAPID PROTOTYPING SOFTWARE’S: Features of various RP software’s like
Magics, Mimics, Solid View, View Expert, 3 D View, Velocity 2, Rhino, STL View
3 Data Expert and 3 D doctor.

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 Rapid Prototyping:
Data Formats

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 STL File

• The representation method used to describe CAD geometry

varies from one system to another. That is why there was a
need of an interface to transfer CAD data to RP system.
• The STL (STereoLithography) file, as the de facto
standard, has been used in many, if not all, rapid prototyping
systems.
• The STL file, conceived by the 3D Systems, USA, is created
from the CAD database via an interface on the CAD
system.
• This file consists of an unordered list of triangular facets
representing the outside skin of an object.

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 STL File
• There are two formats to the STL file; ASCII format and
the binary format.
• ASCII format –ASCII STL files are LARGE in size and
human readable
• Binary format –Binary STL files are more compact not human
readable
• In a STL file, triangular facets are described by a set of
X, Y and Z coordinates for each of the three vertices and a
unit normal vector with X, Y and Z to indicate which side
of facet is an object.
• An example is shown in Figure.

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 STL File
• There are several acronym for STL
• Standard Triangle Language
• Standard Tessellation Language
• STereoLithography
Solid model of a sphere and a tessellated sphere
There are several advantages of the STL file.
• It provides a simple method of representing 3D CAD data.
• It is already a de facto standard and has been used by most cad systems and rapid
prototyping systems.
• It can provide small and accurate files for data transfer for certain shapes

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 STL File
• There are several acronym for STL
• Standard Triangle Language
• Standard Tessellation Language
• STereoLithography
There are dis-advantages of the STL file as follows
• The file is many times larger than the original CAD data file for a given accuracy
parameter.
• The geometry flaws exist in the STL file because many commercial tessellation algorithms
gives rise to the need for a “repair software” which slows the production cycle time i.e. the
subsequent slicing of large STL files can take many hours.
• The STL file carries much redundancy information such as duplicate vertices and edges.

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 STL File Coarse and Fine
• An STL file is coarse if the • An STL file is fine if the surface
surface model is approximated model is approximated to
to less number of triangles. maximum number of triangles.
• facet size is large • facet size is small
• size of STL file is small • size of STL file is too large
• accuracy of the solid is less • accuracy of the solid is more

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 STL File Problems
• Several problems plague STL files and they are due to the very nature of STL files as they
contain no topological data.
• Many commercial algorithms used by CAD vendors today are also not robust, and as a
result they tend to create polygonal approximation models which exhibit the following
types of errors:
(1) Gaps (cracks, holes, punctures) that is, missing facets.
(2) Degenerate facets (where all its edges are collinear).
(3) Overlapping facets.
(4) Non-manifold topology conditions.

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 STL File Problems

Missing Facets or Gaps

• Tessellation of surfaces with large
curvature can result in errors at the
intersections between such
surfaces, leaving gaps or holes
along edges of the part model.
• A surface intersection anomaly
which results in a gap is shown in
Figure.

Gaps due to missing facets

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 STL File Problems
Degenerate Facets
• A geometrical degeneracy of a facet occurs
when all of the facets’ edges are collinear
even though all its vertices are distinct.
• This might be caused by stitching
algorithms that attempt to avoid shell
punctures.
• The resulting facets generated, eliminate
the shell punctures.

However, this is done at the expense of adding a degenerate facet. While degenerate facets do
not contain valid surface normal, they do represent implicit topological information on how
two surfaces mated. This important information is consequently stored prior to discarding the
degenerate facet.
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 STL File Problems

Overlapping Facets
• Overlapping facets may be generated due to
numerical round-off errors occurring during
tessellation.
• The vertices are represented in 3D space as
floating point numbers instead of integers.
• Thus the numerical roundoff can cause facets to
overlap if tolerances are set too liberally.

Overlapping facets

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 STL File Problems
Non-manifold Conditions: These may be generated because tessellation of the fine
features are susceptible to round-off errors.

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 Consequences of Building a Valid and Invalid
Tessellated Model

Valid Model
• A model is said to be valid if any of the
defects of STL file are not there.
• No missing facets
• No degenerate facets
• No overlapping facets
• Any other abnormalities (no non-
manifold conditions)

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 Consequences of Building a Valid and Invalid
Tessellated Model

Invalid Model
• A model is said to be valid if
any of the defects of STL file
are there.
• No missing facets
• No degenerate facets
• No overlapping facets
• Any other abnormalities (no
non-manifold conditions)

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 STL file repair
• In order that the RP system creates valid 3D objects, the input tessellated file should be valid
one. Therefore there is a need of repairing the invalid input files.
• There are two approaches of repairing these defects found in the invalid STL files.
Generic solution
Special algorithm
The generic solution can address to only two kinds of defects,
• Missing facet problem
• Wrong orientation of the facet problem
One is used to repair other special kind of cases. These cases are;
• Two or special algorithm more gaps meeting at a vertex
• Degenerate facets
• Overlapping facets
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 STL file repair
The following steps are used to detect the gap
present in a STL file and its subsequent repairing.
The algorithm goes like this:
Step-1: Checking for approved edges
• Read the first edge from the STL file.
• Search from the complete list of edges, for a similar edge in the opposite direction.
• If edge in opposite direction exists, the edge is said to be approved and is stored under
a temporary file (e.g., file B).
• For example here, let’s pick edge 1-2, if a similar edge in opposite direction i.e edge
2-1 exists, edge 1-2 will be approved and will be stored in file B.
• If for an edge, the similar edge in opposite direction is not found it is said to be not
approved, then go to step-2.
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 STL file repair

• Step-2: Detection of gaps in the tessellated model

• If any unapproved edge is found that edge is stored in a separate file B1.
• The missing edge or non-existing edge is stored in file-C.
• For example, with reference to the figure, let’s take edge 2-3 and check if it is
approved or not. The edge 2-3 is unapproved as 3-2 edge doesn’t exist. So, 2-3 will be
stored in file B1 and the non-existing edge i.e edge 3-2 will be stored in file-C.
• Similarly repeat the process for all the edges.
• The file-B1 and file-C for the example in figure has been given below.

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 STL file repair

Table 1 File B1 containing unapproved edges

Edge
Vertex 1st 2nd 3rd 4th 5th 6th
1st 2 7 3 5 9 11
2nd 3 5 11 2 7 9

Table 2 File C containing non-existing edges

Edge
Vertex 1st 2nd 3rd 4th 5th 6th
1st 3 5 11 2 7 9
2nd 2 7 3 5 9 11

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 STL file repair

Step-3: Sorting of non-existing edges

• After detecting the non-existing edges that causes the gap,
starting from any edge, all the edges are sorted so as to form a
closed loop in anti-clockwise direction. (refer to the figure -16)
• These sorted edges are stored in a separate file-D.
File D containing sorted non-existing edges Representation of
a gap bounded by
Edge all the sorted
Vertex 1st 2nd 3rd 4th 5th 6th edges
1st 3 2 5 7 9 11
2nd 2 5 7 9 11 3

NOTE: so, we can conclude that starting from any point moving in anti-clockwise direction in a covering all the
vertices forming a closed loop that surrounds a gap gives us file D.
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 STL file repair

• Step-4: Creation of facets for the repairing the gap

• After the edges are sorted now the missing facets are generated one at a time.
• A file E is prepared taking all the vertices in columns starting from the first vertex of the first
edge in file - D. (refer table-3). To create the facets following rules are used.
• First facet will be created taking 1stvertex, 2nd vertex and last vertex. After
creating the first facet the orientation of the facet is checked and the order of the
vertices should be in anti-clockwise direction.
• The first vertex will then be eliminated from the file-E.
• Second facet will be created taking 1st, last but one and last vertices. The
orientation of facet is checked as per the rule.
• Then the last vertex will be eliminated from the file-E.

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 Vertex V3 V2 V5 V7 V9 V11
Facet -1 1 2 - - - 3
Facet -2 E 1 - - 2 3
Facet -3 E 1 2 - 3 E
Facet -4 E E 1 2 3 E
• So according to the rule for facet creation the first facet will be created taking 1st, 2nd and last vertices. So it
will be V3, V2 and V11.
• Now the direction of the facet V3– V2 – V11 if it is in anti-clockwise orientation, we should move to next
step.
• Then V3 will be eliminated from the file E and next facet will be created taking 1st, last but one and last
vertex in the file E. So, the second facet will be created taking V2, V9 and V11.

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• Now, orientation of V2 – V9 – V11 is counter-clockwise, so eliminate last vertex from file E i.e V11.
• Now to create the third facet the rule for facet creation will be repeated, so the third facet will be created
taking 1st, 2nd and last vertices. So it will be V2, V5 and V9.
• Eliminate V2, check orientation.
• The fourth facet will be created taking 1st, last but one and last vertex from file E. so, it will be V5 – V7 – V9.
• As all the facets that were missing are created, the algorithm will stop.
• Following figure represents complete process steps of facet creation.

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 STL file repair

Step-1: Checking for approved edges

Step-2: Detection of gaps in the tessellated model

Step-3: Sorting of non-existing edges

Step-4: Creation of facets for the repairing the gap

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 STL file repair: Wrong Orientation

• If the order of vertices in a facet is in clockwise direction then, it is said to be

in wrong orientation. As per the STL file rule the vertices should be ordered in
counter-clockwise direction.

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 Other Formats: IGES Format

• It stands for Initial Graphics Exchange Specification. It is a standard used to

interchange graphics information between CAD systems and set up as American
National Standard in 1981.
• IGES file can precisely represent CAD models as it includes
• Geometry information (Parameter Data Section) & Topological information
(Directory Entry Section)
• In the IGES, surface modeling, constructive solid geometry (CSG) and boundary
representation (B-rep)are introduced.
• In IGES the solid objects are represented by the entities like lines, arcs, splines,
NURBS surfaces and solid elements.

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 IGES Format
Advantages of IGES
• As this format contains both geometry information and topological information and the solid is
represented by several improved entities, data of IGES are more precise.
• Since IGES was set up as American National Standard, virtually every commercial CAD/CAM
system has adopted IGES implementations.
• Data files are much smaller as compared to STL files and the control is also simpler.
Disadvantages
• Because IGES is the standard format to exchange data between CAD systems, it also includes much
redundant information that is not needed for rapid prototyping systems.
• The algorithms for slicing an IGES file are more complex than the algorithms slicing a STL file.
• The support structures needed in RP systems such as the SLA cannot be created according to the
IGES format.

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 HP/GL Format
• It stands for Hewlett-Packard Graphics Language
• HP/GL is a standard data format for graphic plotters.
• Data types are all two-dimensional, including lines, circles, splines, texts, etc.
• Advantages
• A lot of commercial CAD systems have the interface to output the HP/GL format
• It is a2D geometry data format which does not need to be sliced if used as input in RP system..
• Disadvantages
• As HP/GL is a 2D data format, the files would not be added, potentially leaving hundreds of small
files needing to be given logical names and then transferred.
• Second, all the support structures required must be generated in the CAD system and sliced inthe
same way as the actual 3D object.

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 Rapid Prototyping Softwares
Various RP software’s like
Magics,
Mimics,
Solid View,
View Expert,
3 D View,
Velocity 2,
Rhino,
STL View
3 Data Expert and 3 D doctor.

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 Materialise Magics Software

• Materialise Magics is a versatile, industry-leading data preparation and STL editor

software for Additive Manufacturing that allows us to convert files to STL, repair errors,
edit design and prepare build platform.
• This extensive and user-friendly toolbox will help to save time on data preparation,
printing and finishing, thereby significantly reducing the lead time of the projects.
• Smart data preparation leads to less material usage and a higher amount of successfully
printed parts and hence reducing data preparation costs.
• This is the top data preparation software choice for companies and industries worldwide.
It can prepare the data for any RP process.

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 Materialise Magics Software
The tasks that Magics can perform is given below,
• Can import nearly all file formats, Repairing and optimizing 3D models (including the
most difficult ones), Orient the parts, Generate the supports for metal parts, Analyzing
parts, Making process-related design changes on STL files, Designing fixtures,
Documenting projects, 3D nesting the parts, Can edit and enhance the files by adding
logos, serial number, texture etc.

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 Mimics (Materialise Interactive Medical
Image Control System) Software
• This software was also developed for 3D design and modeling in the biomedical applications and
used to create 3D surface models from stacks of 2D image data. These 3D models can then be
used for a variety of engineering applications.
• Materialise Mimics calculates surface 3D models from stacked image data such as Computed
Tomography (CT), Micro CT, Magnetic Resonance Imaging (MRI), Confocal Microscopy, X-ray and
Ultrasound, through image segmentation.
• Most common input format is DICOM, but other image formats such as: TIFF, JPEG, BMP and Raw
are also supported.
• The output formats are: STL, VRML, PLY, DXF and apart from these the output can also be
transferred to ANSYS, Abaqus for analysis or to CAD for further processing.
• The Mimics software comes in two packages, Mimics innovation suite – for engineers and
researchers and Mimics care suite – for health care professionals

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 Solid View Software
SolidView software allows non-CAD users to easily view, measure, translate and markup CAD data, opening up
communication to all who need to be involved in the design process.
• It’s a low-cost solution to access CAD data for manufacturing engineers, scientists, structural engineers,
technical illustrators, managers, product managers and sales people.
• The product allows the user to view measure and modify STL, SLDPRT, SLDASM, VRML, SVD and SFX
files files (the SVD format can be created from any file opened by a user with SolidView).
• Instead of 2D drawings, SolidView can be used. By giving everyone involved in the product development
and support process a 3D view they can move, scale, rotate and measure, their understanding of the data will
be increased and their productivity will be improved.
The advantages of SolidView over 2D drawings include:
• Users can view and measure the 3D data, Valuable engineering time is not wasted on creating 2D drawings
• Users can directly view up-to-date CAD data instead of outdated 2D drawings
• Complex designs and assemblies can be viewed on a low-cost PC, saving plotting paper and supplies and
reducing the security risk of drawing disposal
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 Rhino Software
• Rhino can create, edit, analyze, document, render, animate, and translate NURBS curves,
surfaces, and solids, point clouds, and polygon meshes.
• There are no limits on complexity, degree, or size beyond the size of the hardware of the user.
Special features include:
• Uninhibited free-form 3-D modeling tools like those found only in products costing 20 to 50
times more.
• Model any shape you can imagine.
• Accuracy needed to design, prototype, engineer, analyze, and manufacture anything from an
airplane to jewelry.

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 Rhino Software
• Compatibility with all your other design, drafting, CAM, engineering, analysis, rendering,
animation, and illustration software.
• Read and repair meshes and extremely challenging IGES files.
• Accessible. So easy to learn and use that you can focus on design and visualization without
being distracted by the software.
• Fast, even on an ordinary laptop computer. No special hardware is needed.
• Development platform for hundreds of specialty modeling products. (Windows only)
• Affordable. Ordinary hardware. Short learning curve. Affordable purchase price. No
maintenance fees

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 Thank you

SINGURU RAJESH
[Link] (MD), PGDEEM, [Link] (ME)

Assistant Professor
Raghu Engineering College(Autonomous)
Dakamarri, Bhimunipatnam Mandal,
Visakapatnam Dist, Andhra Pradesh

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