Implementation of a new adaptive slicing algorithm for the rapid prototyping manufacturing system

Rapid prototyping is an automated manufacturing process that quickly builds physical models from three-dimensional (3-D) prototype computer-aided design files. It dramatically speeds up design and manufacturing processes and substantially reduces the cost. This paper presents a new adaptive slicing algorithm for rapid prototyping (RP) processes. The proposed adaptive slicing approach determines the layer thickness based on comparing the contour circumference or the center of gravity of the contour with those of the adjacent layer. Most commercial rapid prototyping systems use uniform slicing procedures with a fixed layer thickness to build parts. To implement the adaptive slicing algorithm, we developed a thermal extrusion based RP mechatronics system equipped with a linear planar servo motor. The RP material is wax. The XYZ table is controlled using a PC based multi-axis DSP motion controller. The RP material flow rate for the thermal extrusion head is controlled using a dc servo motor and motion controller. The Taguchi method was used to analyze the process parameters for the proposed RP system to improve the quality of the RP part. Based on the experimental results, the proposed RP mechatronics system can produce good quality RP parts with the adaptive slicing algorithm. The proposed RP system also implements the high-precision exterior, high-speed interior slicing strategy for STL models.