Conformed-to-CAD Design Sloped-Edge Adaptive Splicing

Many mathematical and simulation based researches have shown the effectiveness of adaptive and angular slicing and layering in minimizing errors in layered manufacturing processes and improving surface quality and build time. Recent technological advances such as 5-axis laser cutters, abrasive waterjets, and CNC machines have enabled physical part fabrication beyond typical vertical layered manufacturing with staircase errors. In this paper, a new curvedform adaptive slicing method is presented. In this method, multiple cuts of the edge boundary of each adaptive layer with variable cutting vector angles conform well to CAD model curved surfaces. The proposed system is compatible with 5-axis abrasive waterjet machines. This system has been successfully tested on several virtual 3D CAD models.Mechanical Engineerin