Course : Digital Fabrication and Architecture
Unit 5 - File to Factory Process
AR3016 | Semester VII | IV Year
Course faculty and Preparation by
Asst. Prof. SRINATH V [Link], MUM.,
File to Factory Process – 3D Printer ( Prototyping )
Slicing softwares are the ones that regenerates a CAD Model to a CAM compatible model,
showing layered model for understanding how a designed model will be produced. At a given
point of time, Slicing software can inform like materials consumed, time left for printing each
and every part of the model etc.,
Slicing Softwares - A CAM Software for 3D Prototyping printers
A 3D protyping printer will require a slicing software to perform the following
1. To visualise the designed CAD model into layers of size in range of 0.25mm to 0.05mm
2. To generate structural voids within the 3D model for producing a better built quality
prototypes
3. To generate and visualise support systems for cantilevered parts of the designed CAD model
4. Tool path simulation and check if prototype model could print as per design
5. To manipulate the settings of the 3D printer
File to Factory Process – 3D Printer ( Prototyping )
LAYERING PROCESS - CAD visualised in layered fashion
The layering purpose of slicing softwares enables the designers to
visualise the various layers of 3D CAD model designed that is to be
prototyped by the 3D Printer
The layers thus formed are the layers of the material chosen for 3D
Printing that majorly inlcude either PLA or ABS plastics
The setting can be done by chosing the thickness of the layers of the
model. This is done for bringing out better finishing to the 3D model
produced. The lower the layer thickness, smoother is the finishing. The
nozzle enables adjusting itself for varying thicknesses.
To visualise the designed CAD model
into layers of size in range of 0.25mm
to 0.05mm
File to Factory Process – 3D Printer ( Prototyping )
VOIDING PROCESS - an Infilling technique
The Structural voids / Infilling technique offers saving of material
required for 3D printing.
Instead of filling the thickness of various components of 3D model with
printing material, Slicing software generates infills that offers structural
stability as well as materials saving for 3D prototyped model.
Comes in various shapes and modes suiting 3D CAD Models
Highly packed voids within the model
represents structurally safe models
and vice versa.
File to Factory Process – 3D Printer ( Prototyping )
SUPPORT SYSTEMS - A solution for complicated components
The support systems are generally done with more thin filaments that
are easily removable after producing the prototype models
The support systems serves to be an element that physically supports
any cantilevered parts of the model
Thus before cantilevered models are layered, the 3D printers create a
support system first and then prints the cantilevered parts of the
model
Optimisation of support systems can be done with 3D printer settings
File to Factory Process – 3D Printer ( Prototyping )
Simulation - A checking process
The 3D CAD Model thus included with necessary settings done,
before its execution for producing a physical model, a simulation
could be done for analysing errors within the model in a layered
fashion
The simulation in slicing software by fixing at a set time can
indicate the position of the extruder and visualise the layer at
which the prototyping is done
Thus before execution of the 3D printing, a tool path generation is
done for the extruder to move in a said manner for producing the
model effectively
After verifying the simulation manually, the model could be
exported with G-Codes for the sharing with 3D Printers for
producing the model
CAD model sliced are converted to G-Code programmes for
commanding 3D printers for printing
File to Factory Process – CNC Cutting
Step 1 - CAD Model Generation - CAD Based 3D Model shall Step 2 - Toolpath Generation - The 3D model imported into
be designed for the CAM to read its geometries for fabrication CAM software then reads the 3D CAD model and defines
through CNC (Computer Numerical Control) milling machine. various paths on the model for guiding the CNC Miller bits to
The CAD the data of dimensions included into the designed 3D move on the path defined, for subtracting the raw material as
Model. per 3D model designed.
CAD is a software application used to create, modify, and optimize a CAM is software that translates a CAD design into instructions for
design. It's essentially a digital drawing board where you can create 2D manufacturing machines. It takes the digital design and converts it into
and 3D models of products. a set of commands for machines like CNC (Computer Numerical Control)
machines, robots, and 3D printers.
File to Factory Process – CNC Cutting
Step 3 - Toolpath
Step 4 - Exporting in ISO format - Generally,
Generation Simulation -
conversion of Model into ISO file will lead to
The toolpath thus
generating of G-Codes for the CAM
generated will be
machineries to read and act accordingly. Each
digitally simulated for
G-code is a digital programme and could
detecting errors and
make machines operate in specific actions
ensuring of perfection.
respective to the G-Code.
Hence, after successful
checking can proceed for
eg: G28 - can make the CNC Miller bit to
CNC Milling.
move back to its reference position
File to Factory Process – Mesh Optimization
Mesh optimization is a crucial step in digital fabrication, as it directly impacts the quality, efficiency, and success of the final product. It
involves refining a 3D mesh to reduce its complexity while preserving its essential geometric features.
Key Techniques for Mesh Optimization:
Simplification:
Vertex Removal: This technique involves removing redundant vertices, especially those that have minimal impact on the overall shape.
Edge Collapse: Edges that are short or have a low impact on the shape can be collapsed, reducing the number of polygons.
Quadric Error Metric (QEM): This method calculates the error introduced by removing a vertex or collapsing an edge, allowing for more
intelligent simplification.
Remeshing:
Regularization: This involves converting an irregular mesh into a more regular one, often with a uniform distribution of triangles or quads.
Smoothing: This technique reduces noise and sharp features in the mesh, resulting in a smoother and more aesthetically pleasing surface.
Topology Optimization:
This involves removing material from a design while maintaining its structural integrity. It can be used to create lightweight and efficient
structures.
Texture Mapping:
Optimizing texture maps involves reducing the resolution or compressing the image data to minimize file size without sacrificing visual
quality.
File to Factory Process – Mesh Optimization
Tools and Software for Mesh Optimization:
MeshLab: An open-source software for processing and cleaning 3D triangular meshes.
Blender: A powerful 3D modeling and animation software with robust mesh editing tools.
Geomagic Wrap: A commercial software for 3D scanning and reverse engineering, which includes powerful mesh optimization features.
CAD Software: Most CAD software packages have built-in tools for mesh simplification and repair.
Importance of Mesh Optimization in Digital Fabrication:
Improved Print Quality: Optimized meshes can lead to higher-quality 3D prints with fewer artifacts and better surface finish.
Reduced Print Time: Simpler meshes can be printed faster, saving time and material costs.
Smaller File Sizes: Optimized meshes require less storage space and transfer faster.
Better Compatibility: Optimized meshes are more compatible with different 3D printing software and hardware.
Enhanced Simulation Accuracy: Accurate mesh representation is crucial for simulations like finite element analysis (FEA) and
computational fluid dynamics (CFD).
By effectively optimizing meshes, designers and engineers can achieve better results in digital fabrication, leading to more efficient and
cost-effective production processes.