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Majority of the existing direct slicing methods have generated precise slicing contours from different surface representations, they do not carry any interior information. Whereas, heterogeneous solids are highly preferable for designing and manufacturing sophisticated models. To directly slice heterogeneous solids for additive manufacturing (AM), this study aims to present an algorithm using octree-based subdivision and trivariate T-splines.

This paper presents a direct slicing algorithm for heterogeneous solids using T-splines, which can be applied to AM based on the fused deposition modeling (FDM) technology. First, trivariate T-splines are constructed using a harmonic field with the gradient direction aligning with the slicing direction. An octree-based subdivision algorithm is then used to directly generate the sliced layers with heterogeneous materials. For FDM-based AM applications, the heterogeneous materials of each sliced layer are discretized into a finite number of partitions. Finally, boundary contours of each separated partition are extracted and paired according to the rules of CuraEngine to generate the scan path for FDM machines equipped with multi-nozzles.

The experimental results demonstrate that the proposed algorithm is effective and reliable, especially for solid objects with multiple materials, which could maintain the model integrity throughout the process from the original representation to the final product in AM.

Directly slicing heterogeneous solid using trivariate T-splines will be a powerful supplement to current technologies in AM.

T-spline is the latest powerful modeling tool in the field of computer-aided design. It has all the merits of non-uniform rational B-spline (NURBS) whilst resolving some flaws in it. This work applies T-spline surfaces to additive manufacturing (AM). Most current AM products are based on Stereolithograph models. It is a kind of discrete polyhedron model with huge amounts of data and some inherent defects. T-spline offers a better choice for the design and manufacture of complex models.

In this paper, a direct slicing algorithm of T-spline surfaces for AM is proposed. Initially, a T-spline surface is designed in commercial software and saved as a T-spline mesh file. Then, a numerical method is used to directly calculate all the slicing points on the surface. To achieve higher manufacturing efficiency, an adaptive slicing algorithm is applied according to the geometrical properties of the T-spline surface.

Experimental results indicate that this algorithm is effective and reliable. The quality of AM can be enhanced at both the designing and slicing stages.

The T-spline and direct slicing algorithm discussed here will be a powerful supplement to current technologies in AM.

The purpose of this paper is to further simplify the use of NURBS in industrial environnements. Although isogeometric analysis (IGA) has been the object of intensive studies over the past decade, its massive deployment in industrial analysis still appears quite marginal. This is partly due to its implementation, which is not straightforward with respect to the elementary structure of finite element (FE) codes. This often discourages industrial engineers from adopting isogeometric capabilities in their well-established simulation environment.

Based on the concept of Bézier and Lagrange extractions, a novel method is proposed to implement IGA from an existing industrial FE code with the aim of bringing human implementation effort to the minimal possible level (only using standard input-output of finite element analysis (FEA) codes, avoid code-dependent subroutines implementation). An approximate global link to go from Lagrange polynomials to non-uniform-rational-B-splines functions is formulated, which enables the whole FE routines to be untouched during the implementation.

As a result, only the linear system resolution step is bypassed: the resolution is performed in an external script after projecting the FE system onto the reduced, more regular and isogeometric basis. The novel procedure is successfully validated through different numerical experiments involving linear and nonlinear isogeometric analyses using the standard input/output of the industrial FE software Code_Aster.

A non-invasive implementation of IGA into FEA software is proposed. The whole FE routines are untouched during the novel implementation procedure; a focus is made on the IGA solution of nonlinear problems from existing FEA software; technical details on the approach are provided by means of illustrative examples and step-by-step implementation; the methodology is evaluated on a range of two- and three-dimensional elasticity and elastoplasticity benchmarks solved using the commercial software Code_Aster.

Compared with cusp height and area deviation ratio, volume error (VE) caused by the layer height could represent the stair-case effect more comprehensively. The proposed relative volume error (RVE)-based adaptive slicing method takes VE rather than cusp height as slicing criteria, which can improve part surface quality for functionalized additive manufacturing.

This paper proposes a volumetric adaptive slicing method of manifold mesh for rapid prototyping based on RVE. The pre-height sequences of manifold mesh are first preset to reduce the SE by dividing the whole layer sequence into several parts. A breadth-first search-based algorithm has been developed to generate a solid voxelization to get VE. A new parameter RVE is proposed to evaluate the VE caused by the sequence of the layer positions. The RVE slicing is conducted by iteratively adjusting the layer height sequences under different constraint conditions.

Three manifold models are used to verify the proposed method. Compared with uniform slicing with 0.2 mm layer height, cusp height-based method and area deviation-based method, the standard deviations of RVE of all three models are improved under the proposed method. The surface roughness measured by the confocal laser scanning microscope proves that the proposed RVE method can greatly improve part surface quality by minimizing RVE.

This paper proposes an RVE-based method to balance the surface quality and print time. RVE could be calculated by voxelized parts with required accuracy at a very fast speed by parallel.

This paper aims to provide designers/engineers, in engineering structural design and analysis, approaches to freely and accurately modify structures (geometric and/or material), and then quickly provide real-time capability to obtain the numerical solutions of the modified structures (designs).

The authors propose an isogeometric independent coefficients (IGA-IC) method for a fast reanalysis of structures with geometric and material modifications. Firstly, the authors seamlessly integrate computer-aided design (CAD) and computer-aided engineering (CAE) by capitalizing upon isogeometric analysis (IGA). Hence, the authors can easily modify the structural geometry only by changing the control point positions without tedious transformations between CAE and CAD models; and modify material characters simply based on knots vectors. Besides, more accurate solutions can be obtained because of the high order degree of the spline functions that are used as interpolation functions. Secondly, the authors advance the proposed independent coefficients method within IGA for fast numerical simulation of the modified designs, thereby significantly reducing the enormous time spent in repeatedly numerical evaluations.

This proposed scheme is efficient and accurate for modifying the structural geometry by simply changing the control point positions, and material characters by knots vectors. The enormous time spent in repeated full numerical simulations for reanalysis is significantly reduced. Hence, enabling quickly modifying structural geometry and material, and analyzing the modified model for practicality in design stages.

The authors herein advance and propose the IGA-IC scheme. Where, it provides designers to fasten and simple designs and modify structures (both geometric and material). It then can quickly in real-time obtain numerical solutions of the modified structures. It is a powerful tool in practical engineering design and analysis process for local modification. While this method is an approximation method designed for local modifications, it generally cannot provide an exact numerical solution and its effectiveness for large modification deserves further study.