Rapid Prototyping is one of the most dominant emerging technologies that will affect product development in the coming years. Most RP systems are driven via an in-built CAD system. The CAD systems usually read in the part data, through the de facto standard STL file format which is the approximation of the solid model by using triangular facets, and determine related processing information depending on the technology. Most CAM support for those existing RP systems is proprietary. Further, these systems often use inefficient process planning, potentially wasting tremendous amount of machining time. In this thesis, we shall present a new framework for an open architecture process planner for use as a CAD/CAM system for RP technologies, specifically designed for the Laminated Object Manufa...[ Read more ]

Rapid Prototyping is one of the most dominant emerging technologies that will affect product development in the coming years. Most RP systems are driven via an in-built CAD system. The CAD systems usually read in the part data, through the de facto standard STL file format which is the approximation of the solid model by using triangular facets, and determine related processing information depending on the technology. Most CAM support for those existing RP systems is proprietary. Further, these systems often use inefficient process planning, potentially wasting tremendous amount of machining time. In this thesis, we shall present a new framework for an open architecture process planner for use as a CAD/CAM system for RP technologies, specifically designed for the Laminated Object Manufacture (LOM) system. The essential element of the system consists of a direct solid model processing via the use of an embedded solid modeler and direct slicing techniques. An open, compact format for storage of generic slice geometry and topology information is developed. The system incorporates a geometric engine that can be used by several layered manufacturing techniques for improved process planning. There is also an optimization engine that will ensure optimized path planning to save machining time for each layer. Although the proposed system is designed for the LOM system, it is broad enough to be adapted for use by several different RP technologies. The advantages accruing from the proposed CAD/CAM system include open architectural structure for future expansion, processing efficiency, compact data storage, and most importantly, improved manufacturing times and accuracy.