Increasingly, Solid Freeform Fabrication (SFF) processes are being considered for creating functional parts. In such applications, SFF can either be used for creating tooling (i.e., patterns for casting, low volume molds, etc.) or directly creating the functional part itself. In order to create defect free functional parts, it is extremely important to fabricate the parts within allowable dimensional and geometric tolerances. This paper describes a systematic approach to analyzing manufacturability of parts produced using SFF processes with flatness tolerance requirements on the planar faces of the part. Our research is expected to help SFF designers and process providers in the following ways. By evaluating design tolerances against a given process capability, it will help designers in eliminating manufacturing problems and selecting the right SFF process for the given design. It will help process providers in selecting a build direction that can meet all design tolerance requirements.

Issue Section:
Technical Papers
Keywords:
manufacturing processes, machine tools, tolerance analysis, design for manufacture, CAD/CAM, assembly planning
Topics:
Algorithms, Design, Errors, Manufacturing, Stairs, Stereolithography, Geometry
1.
Rajagopalan, S., Pinilla, J. M., Losleben, P., Tian, Q, and Gupta, S. K., 1998, “Integrated Design and Manufacturing Over the Internet,” in Proceedings of the ASME Computers in Engineering Conference, Atlanta, GA, September.
2.
Tumer, I., Thompson, D. C., Crawford, R. H., and Wood, K. L., 1995, “Surface Characterization of Polycarbonate Parts from Selective Laser Sintering,” in the Proceedings of the Solid Freeform Fabrication Symposium, Austin, TX. August 7–9.
3.
Gervasi, V. R., 1997, “Statistical Process Control for Solid Freeform Fabrication Processes,” in the Proceedings of Solid Freeform Fabrication Symposium, Austin, pp. 141–148, August 11–13.
4.
Rosen, David W., Sambu, Shiva Prasad, and West, Aaron P., 2001, “A Process Planning Method for Improving Build Performance in Stereolithography,” accepted for publication in Computer-Aided Des.
5.
Onuh, S. O., and Hon, K. K. B., 1997, “Optimizing Build Parameters and Hatch Style for Part Accuracy in Stereolithography, in the Proceedings of Solid Freeform Fabrication Symposium, Austin, pp. 653–660, August 11–13.
6.
Tata, K., and Flynn, D., 1996, “Quantification of Down Facing Z Error and Associated Problems,” in the Proceedings of NASUG Conference, San Diego, March 11–13.
7.
Frank, D., and Fadel, G. F., 1994, “Preferred Direction of Build for Rapid Prototyping Processes,” in the Proceedings of the Fifth International Conference on Rapid Prototyping, Dayton, OH., pp. 191–200.
8.
Cheng
,
W.
,
Fuh
,
J. Y. H.
,
Nee
,
A. Y. C.
,
Wong
,
Y. S.
,
Logh
,
H. T.
, and
Miyazawa
,
T.
,
1995
, “
Multi-Objective Optimization of Part Building Orientation in Stereolithography
,”
Rapid Prototyp. J.
,
1
, No.
4
, pp.
12
–
23
.
9.
Pududhai, N. S., and Dutta, D., 1994, “Determination of Optimal Orientation based on Variable Slicing Thickness in Layered Manufacturing.” Technical report UM-MEAM-94-14, Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI.
10.
Bablani
,
M.
, and
Bagchi
,
A.
,
1995
, “
Quantification of Errors in Rapid Prototyping Processes, and Determination of Preferred orientation of Parts
,”
Trans. North Am. Manufact. Res. Inst. SME
,
23
, pp.
319
–
324
, May.
11.
Thompson, D. C., and Crawford, R. H., 1995, “Optimizing Part Quality with Orientation,” Solid Freeform Fabrication Symposium, University of Texas, Austin, August.
12.
Suh, Y. S., and Wozny, M. J., 1995, “Integration of a Solid Freeform Fabrication Process into a Feature-Based CAD System Environment, Solid Freeform Fabrication Symposium, University of Texas, Austin, August.
13.
Ramakrishna, A., 2000, “Web-Based Manufacturability Analysis for Solid Freeform Fabrication,” M. S. Thesis, Mechanical Engineering Department, University of Maryland, College Park.
14.
Gupta, S. K., Tian, Q., and Weiss, L., 1998, “Finding Near-Optimal Build Orientations for Shape Deposition Manufacturing,” in the Proceedings of Sculptured Surface Machining Conference, Auburn Hills, MI., October.
Copyright © 2001
 by ASME
You do not currently have access to this content.