Multi-axis Rapid Prototyping

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Multi-axis Rapid Prototyping
Neil Sewell Dr. Martin Jenkins Dr. Richard
Everson
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Overview

• What is RP, why use it, who uses it?
• Previous work
• Current work and Future work
• Lab demonstration

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Rapid Prototyping 3 types

• Type 1 - DTM Laser sinterstation

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Rapid Prototyping

• Type 2 - 3D Systems Stereolithography

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Rapid Prototyping

• Type 3 - 3D Printers

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RP Why use it?

• Injection moulds are expensive to produce
• One-off test pieces can be used in real world
• Great for real world ergonomic testing

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RP Who uses it?

• Virtually all major device manufacturers
• Designers Prototypers
• One-off producers

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Previous work...

• SARP is Single Axis Rapid Prototyping

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SARP Single Axis RP

• SARP is quick, cheap and easy.
• Allows building of quite complex models
• Is fast and efficient
• But
• Will not allow for large overhangs
• Is not to the same resolution

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Examples of SARP

• Cubes
• Spheres
• Arches
• Logos

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Current work...

• MARP is Multi Axis Rapid Prototyping
• Still uses VMC, Hot glue nozzle and glue
• Different, more complex software
• Add-on 4th and 5th Axis units to rotate models

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MARP Multi Axis RP

• Models with overhangs could be built
• Building direction is continuously changed
• Models created would of better quality
• The process would be quicker

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How to MARP Step 1

• Perform analysis of object - create a usable data
  structure.

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How to MARP Step 2

• Select start location direction

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How to MARP - Step 3

• Start the edge following process

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How to MARP Step 4

• Create machine instructions
• Use glue path to locate x,y,z position
• Use facet data to provide rotation values
• Use collision detection methods!

(Lab demonstration at end of presentation)
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Latest Work

• Uses many rules
• Edge vector creation analysis
• Unnecessary edge deletion detection
• Improvement Optimisation techniques
• Current problems include
• Holes in model
• Sticky tight corners
• Finishing problems

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Conclusion

• MARP work is going well - But is difficult
• Software
• Multiple data lists
• Edge following
• Uses Downhill Simplex Method
• Started testing Simulated Annealing

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Conclusion

• Realism with MARP - What can it build?
• Difficult shapes
• Disjoint shapes
• Really complex shapes?

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Thank you for listening

• Questions
• Visit to lab for Multi-Axis demonstration