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A processing algorithm for freeform fabrication of heterogeneous structures is presented. The algorithm was developed based on the heterogeneous fabrication structural model, which was constructed from the STL based multi‐material volume regions and with material identifications. The reasoning Boolean operation based modelling approach was used to construct the heterogeneous CAD assembly and to output the needed STL format. Procedures for generating the database hierarchy and the storage of the heterogeneous structural model, and derivation for developing the processing algorithm for layered fabrication of heterogeneous structure are presented. The developed algorithm was applied to a heterogeneous structure consisting of two discrete material volumes, and the detailed processing path is described.

The representation of Heterogeneous Object (HO) is divided into two categories: Data model (DM) and material evaluation paradigm (MEP). A hybrid methodology with geometry model and volumetric dataset to represent heterogeneous properties is proposed in this paper. Geometry model of an object can guarantee the accuracy of the final HO slices; and volumetric dataset lends the flexible manipulability and other advantages to HO representation. Two MEPs, namely distance field (DF) based and Fixed Reference Features & Active Grading Source(s) (FRF&AGS) are presented to facilitate the process of HO representation according to the designer)s input parameters. The DM can be modified interactively with users until the final satisfactory result is obtained. In this paper, a scheme of HO slicing is described. In this method, we utilize the slices contour of geometrical model as constraint to reconstruct the HO slices, which can theoretically achieve the same accuracy with the geometrical shape. Some examples of Heterogeneous object represented with our scheme are provided.

Apart from the geometries to be dealt with, rapid prototyping (RP) of heterogeneous objects requires additional material information to be processed. This generally involves a large amount of information to be processed simultaneously. The robustness and efficiency problems, which seem less critical in homogeneous solid fabrications, become an issue. The direct impetus of this paper is to present robust and efficient algorithms for RP of heterogeneous objects.

The robustness is benefited from using the proposed non‐manifold heterogeneous cellular model, which guarantees gap‐free material depositions around material interfaces. The efficiency enhancement is achieved by eliminating repetitive boundary intersections and using a heuristic material interrogation approach.

By using the proposed algorithms, the robustness and efficiency of RP of heterogeneous objects can be improved. It is found that an average 30 percent efficiency improvement is obtained using the proposed heuristic material interrogation approach.

Non‐manifold heterogeneous cell representation (HC‐Rep) is used in RP fields for the first time. Based on the HC‐Rep, the robustness and efficiency of RP of heterogeneous object is addressed in this paper.

Computer aided design systems are routinely used by designers for creating part geometries. Interfaces to computer aided analysis and manufacturing are also commonplace enabling the rapid fabrication of the designed part. Thus far, however, the focus was on objects with homogeneous interior. Two recent advances use of functionally graded materials in parts, and layered manufacturing technology have brought to the forefront the need for CAD systems to support the creation of geometry as well as the graded material inside. This paper reports on such a system. We describe the need, the components and implementation of a CAD system for creating heterogeneous objects. Two examples illustrate the use.

In order to represent, analyze, optimize, and manufacture a component made of multi‐heterogeneous materials for high‐tech applications, a computer model of the heterogeneous component needs to be built first. Heterogeneous materials include composite, functionally graded materials, and heterogeneous materials with a periodic microstructure. Current modeling techniques focus only on capturing the geometric information and cannot satisfy the requirements from modeling the components made of multi‐heterogeneous materials. This paper develops a modeling method, which can be implemented by employing the functions of current CAD graphic software and can obtain the model including both the material information (about its microstructures and constituent composition) and the geometry information without the problems arising from too many data.

Information models for the representation of product data are being developed as an international standard. However, the current application protocols focus on the representation of homogeneous objects only. This paper suggests an information model to represent heterogeneous objects using the information modeling methodology developed for ISO 10303. The data planning model is then extended to represent the two‐dimensional (2D) slice information using concepts from ISO 10303. The proposed formats are validated by physical realization of objects on two LM machines. This information model will help in providing a uniform base in the development of heterogeneous solid modeling systems. It will also equip the solid modeler with the ability to integrate with other applications and process planning in the domain of layered manufacturing.

The purpose of this paper is to present a new method for representing heterogeneous materials using nested STL shells, based, in particular, on the density distributions of human bones.

Nested STL shells, called Matryoshka models, are described, based on their namesake Russian nesting dolls. In this approach, polygonal models, such as STL shells, are “stacked” inside one another to represent different material regions. The Matryoshka model addresses the challenge of representing different densities and different types of bone when reverse engineering from medical images. The Matryoshka model is generated via an iterative process of thresholding the Hounsfield Unit (HU) data using computed tomography (CT), thereby delineating regions of progressively increasing bone density. These nested shells can represent regions starting with the medullary (bone marrow) canal, up through and including the outer surface of the bone.

The Matryoshka approach introduced can be used to generate accurate models of heterogeneous materials in an automated fashion, avoiding the challenge of hand-creating an assembly model for input to multi-material additive or subtractive manufacturing.

This paper presents a new method for describing heterogeneous materials: in this case, the density distribution in a human bone. The authors show how the Matryoshka model can be used to plan harvesting locations for creating custom rapid allograft bone implants from donor bone. An implementation of a proposed harvesting method is demonstrated, followed by a case study using subtractive rapid prototyping to harvest a bone implant from a human tibia surrogate.

This paper describes the elastic state of heterogenous materials within the framework of the mechanics of heterogenous continua. Failure condition of a two‐phase material is formulated and the dependencies of hydroabrasive and cavitational wear of steel on the spacing of the inclusions of martensite in steels with ferritic‐cementitic and austenitic structures are established. The dependence of the wear resistance criterion on the stress, distribution density and austenitic grain diameter is also presented. The results made it possible to develop an effective structure‐energy model to describe wear processes of materials and coatings.

The purpose of this paper is to explore and develop specific models of the kinetics of isothermal depolarization currents (IDC) and the corresponding methods for the diagnostics of the physical parameters of localized electronic states (LES) in heterogeneous materials and corresponding polycrystalline semiconductor materials and heterogeneous insulators with a conductive phase.

Analysis of the kinetics of isothermal depolarization on the basis of the models allowed the authors to establish a sufficient level of their information content. This also allowed the possibility of applying for research and testing of heterogeneous structures of electronic technique.

Optimal conditions (full charge of LES on one side of the object and full discharge on the other side) and the correction factors, allowed the researchers to find concentration of these states using the developed models.

This paper uses a particular method to determine and test the parameters of LES, including operations of determining the time constant of IDC signal from its frequency spectrum, finding the ionization energy and the capture coefficient of electrons from the temperature dependence of this time constant, determining the concentration based on the integration of the time dependence of current density of IDC in the time interval that boundaries are determined from the limited range of frequencies of the signal IDC spectrum has been proposed, validated and verified by numerical experiments.

This paper aims to present a digital image processing (DIP)-based discrete element method (DEM) for the analysis of heterogeneous geomaterials. Taking a soil and rock mixture as an example, the direct shear test is used to illustrate the application of this method. The numerical result is validated by the laboratory experiment and implies its feasibility in the analysis of heterogeneous geomaterials.

This method has two major steps. Based on a modification of the connected-component labeling algorithm, a novel vectorization method, which can transform the digital photos to vectorized geometry automatically, is proposed first. Then, a simple yet effective method for the generation of heterogeneous DEM models is presented using the simulation of simplicity technique.

DIP-DEM method is a feasible approach for the analysis of mechanical behavior of heterogeneous material. For soil and rock mixtures (SRM), the horizantal deformation at peak shear point becomes larger with the normal stress. Compared with pure soil, the rock aggregates mainly improve the friction angle of SRM.

As a universal method taking advantage of both DIP and DEM, this method has broad application prospects in related fields.