What does STL stand for? How is represented and why is it suited for digital manufacturing?

Standard Triangulation Language (Sometimes STereoLithography).

It is an approximation of an objects surface in form of a triangular mesh.
The vertices are numbered 1-3 in a "right hand rule" were the thumb indicate the outer side
of the triangle. Computational easy to slice.
Geometric data can be represented in three different ways, which?
Wireframe representation
Boundary representation (B‐rep)
Constructive solid geometry (CSG)
What is reverse engineering?
The process of duplicating an existing part, subassembly or product without drawings and
documentation.
What are the three main technologies for reverse engineering data acquisition?
Contact, noncontact and destructive
One part of reverse engineering is to digitize (obtain a computer model) an existing product.
Describe a contact, point to point scanner
Probe mounted on either an articulated arm or a CMM machine.
Touch trigger probe moves incrementally and touches the surface (not dragging the probe -
analogue
sensing)
Reads coordinates on the objects surface
Explain the difference between CL data and G,M codes?
CL - machine independent
G,M - Machine specific
Describe Constructive Solid Geometry (CSG)
Allows a modeler to create complex surface or object using Boolean operators to combine
objects.
What is the difference between active and passive stereo in non contact scanning?
Passive - no active forms of illumination
Explain Active stereo illumination
Continuous wave system. Measures the phase change of the laser light wave as it travels from
the laser - object - detector. Gives the object distance.
Name four advantages using contact scanning compared to noncontact scanning
•High accuracy
•Low cost (depends)
•Ability to measure deep holes and slots
•Insensitivity to color or transparency
What are the acronyms CAD, CAM and CIM?
Computer aided Design - Computer Aided Manufacturing - Computer Integrated Manufacturing
Name the three most common sources of illumination for active non contact scanners. Which
one is used by the Goscan used in the course?
Single point laser - sheet of light - coded light pattern. Goscan - coded light pattern
The rapid prototyping process can be divided into 4 steps, which are they?
3D Modeling - Data conversion & Pre‐processing - prototyping & fabrication - post processing
How does CT and MRI scanning work? No details required
2D cross sectional images are captured of an object.
The images are analyzed by vision software to convert the digital bitmap to edge detected
points. The cross sectional images are then combined to represent the object in 3D
Name two disadvantages using rapid prototyping techniques compared to traditional
manufacturing
Accuracy general > 0.1 mm - Material properties - staircase effect
What does the 3D printing method SLA stand for and how does it work?
Stereolithography apparatus.
A platform in a bath of photosensitive UV curable resin.
The platform is connected to an elevator which descends layer by layer in the bath. A UV laser
cures desired areas one layer at a time. Support structures needed. Post curing is needed in an
UV oven.
What are the two basic steps in the adaptive slicing approach for cloud data modeling?
Slicing the point cloud data into a number of layers of points Constructing a layer represented
by a 2D contour and a certain thickness.
Name two advantages using the three dimensional printing (3‐DP) used in the course
Full color - low powder waste - cheap - off the shelf print head
A sampling method (software) called - curvature - can be used when scanning objects, how
does it work?
Fewer points are deleted in regions with high curvatures then in low curvature regions. This to
maintain accuracy and reduce points.
What are the problems using a "traditional product development process"?
Long development process - lack of communication - costly - time inefficient
There are several feature recognition techniques to extract features from 3D CAD models.
Name two
Syntactic pattern rec. approach - logic based approach - graph based approach - ES/artificial
intelligence approach - volume decomposition and composition approach - 3D feature
recognition from 2D features approach.
Describe an alpha, beta and a production prototype
Alpha - subsystem individually proven to work
Beta - full scale functional prototype - actual material as final product
Production - final full scale physical model using the actual production tooling
What is a virtual prototype? Give an example
A digital prototype such as a CAD model, CFD, Matlab etc.
Describe the Reverse engineering destructive method and when it is a good alternative
compared to other RE methods
A CNC milling machine exposes 2‐D cross‐sectional (slice) images which are gathered by a CCD
camera. Useful for small and complex objects were both internal and external features are
needed.
What does a postprocessor do?
Adapt CL codes (machine independent) from CAM to a specific machine (G, M codes - machine
specific)
What type of solid modeling is Solid Edge mainly based on?
CSG
What are the two types of data collection techniques used in contact scanning
Point to point sensing - analogue sensing
SFS is a passive method to reconstruct 3‐D models. What does it stand for and briefly explain
how it works?
Shapes from shading. Reconstructing a 3D representation of an object from a single image (2‐D
input) based on shading information. Only ambient light.
Occlusion can be a problem when scanning objects. Describe short what it is and how it can be
avoided
The object may hide both the laser and the camera from viewing different surfaces on the
object. Multiple views can help or using a different type of scanner (probe).
What is the main advantage with a CMM contact scanner compared to non contact scanners?
Accuracy
Define CAM
Computer based software tools that assists manufacturing and prototyping
Define CIM
A manufacturing method in which the entire production process is controlled by computer
What are the four main phases in the RE data processing chain, scan to solid ?
Points and images - polygon - curves - NURBS surfaces
There are many reasons to use reverse engineering. One is for quality control of manufactured
products. Explain briefly how
Control and comparing of fabricated parts to its CAD model by the usage of a high resolution 3D
scan of the part. Statistical analyzes can be made on the measurement deviations.
Computerized tomography (CT) and Magnetic resonance imaging (MRI) scanning has one major
advantage compared to optical and probe scanning, what?
It also scans the internal features of an object.
A lot of RE software packages provide automatic creation of NURBS patches. Why does it
usually become a problem when using it?
Usually features such as edges and primitives cannot be recognized and the patches do not
adequately define the surface curvature. Manual organization of the patch structure is almost
always required
What does the 3D printing method LOM stand for and how does it work?
Laminated Object Manufacturing. A sheet of paper (unwound from a feed roll) with coating on
reverse side is placed on a platform. The sheet is heated to attach to the layer beneath. A
carbon dioxide laser cuts out cross sections. A new layer is added and the procedure repeats.
What is concurrent engineering and name at least two benefits
A Constructive solid geometry representation (CSG) of a solid model is analogous with
manufacturing techniques such as milling and lathing, explain?
Explain boundary representation
Describes the geometry of an object in terms of its boundaries (vertices, edges and surfaces)
According to the literature there are six types of solid modeling representations, name three.
Boundary representation, Constructive solid geometry, Cell decomposition, Spatial occupancy
enumeration, Primitive instancing, Sweeping
What is the main disadvantage with a CMM contact scanner compared to noncontact scanners
Scanning time
How does contact scanning, using analogue sensing technique, work?
The scanning probe provides a continuous deflection output as it moves along a surface - thus
gathering data.
Manufacturing a RP model based on RE will involve shape errors. Mainly the error comes from
three sources, name two.
Shape error between cloud data and NURBS model - Shape error between NURBS model and
STL - shape error between STL and the layer based RP model
What does the 3D printing method FDM stand for and how does it work?
Fused Deposition Modeling. Build and support material on spools, fed through a liquefier and
deposit on a plate through a nozzle, the build tray descends after each layer, support material is
used to support the model material. Support is later dissolved.
Name the three major categories of active stereo illumination
Continuous wave - time of flight - structured light triangulation
What is forward engineering?
Traditional process, moving from high‐level abstraction and logical design to the physical
implementation of a system. Calculations - drawings - manufacturing
When scanning objects three different samplings methods can be utilized to minimize the
number of points in the point cloud data. Name these methods.
Curvature - random - uniform
Name one drawback using automatic creation of NURBS from polygon models
A lot of small NURBS surfaces - hard to work with
If you need to scan an object and want a resolution of 0.001 mm, what type of equipment
would you use?
Contact scanning, point to point sensing.
State the different solid based RP processes
▪ Extrusion-based processes, FDM (Fused Deposition Modeling)
▪ Contour-cutting processes, LOM (Laminated Object Manufacturing)
▪ Ultrasonic Consolidation process, UC
The additive RP processes can be divided into three categories, which?
Solid, liquid and powder
hat are the two conventional approaches or methods to transform cloud data to CAD
representation (NURBS)?
Triangular polyhedral mesh method - Segment and fit method
6.The acronym SMART is widely used in project management, why and what is missing below?
Specific Measurable A Relevant T
Explain the inject based liquid RP process (Polyjet)
Injection-based liquid process, PolyJet
▪ Hybrid of material printing or jetting Stereolithography
▪ Photo or IV curable resin
▪ UV-bulbs are place alongside the jetting head
▪ 8 jetting heads are used in the process
▪ Gel-like photopolymer as support material (can be removed by a waterjet)
What is DOE?
design of experiments (DOE) or experimental design is the design of any information-gathering
exercises where variation is present, whether under the full control of the experimenter or not
Räknas upp några typiska användningsområden för metoden LOM (Laminated Object
Manufacturing).
▪ Sand castings
▪ Investment castings
▪ Plaster casting
▪ Silicone RTV mold
▪ Vacuum forming
▪ Injection molding
Nämn tre olika "Rapid prototyping" metoder som använder sig av pulver
Selective Laser Sintering process (SLS)
Three Dimensional printing (3-DP)
Direct laser deposition (LENS)
Electronic beam melting process
Nämn några fördelar med EBM metoden
▪ Replaces the laser with an 4 kW electro beam
▪ More energy effective than a laser for conductive materials
▪ Vacuum chamber to get high strength material properties
▪ High build speed
KISS is an acronym for a general design rule. What does this rule means (stand for).
KISS is an acronym for "Keep it simple, stupid" The KISS principle states that most systems work
best if they are kept simple rather than made complicated; therefore simplicity should be a key
goal in design and unnecessary complexity should be avoided
Why is material selection important?
• Material may be more than 50% of the total cost
• In auto industry material cost is about 70% of the total
cost
• In shipbuilding material cost is about 45% of the total cost
• It will affect the manufacturing process, e.g.
- Sheet metal => stamping
- Plastic => injection molding
When selecting materials we can apply two fundamentally different approaches. Which two?
material first
process first
Give some disadvantages of the method SLA (stereolithography).
▪ Waterabsorption in the resin
▪ Result in curling or warping
▪ Relatively high system cost
▪ Parts cannot be used for durability and thermal testing
▪ Post curing is normally needed
Give three different RAPID prototyping methods that use a liquid
▪ Stereolithography process (SLA)
▪ Masked-based process (SGC)
▪ Inject-based liquid process
▪ Rapid freeze prototyping process (RFP)
A Rapid Prototyping RP manufacturing process is considered to be only an additive process.
However, subtractive processes can also be called RP manufacturing. When is it considered to
be an RP manufacturing process?
Technologies that are used to produce physical objects layer-by-layer directly from Computer-
Aided Design (CAD). Referred to as solid free-form fabrication or layered manufacturing. The
term "rapid" is relative and aims at the automated step from CAD data to machine rather than
at the speed of the techniques.
What RP process can make layers as thin as 16μm?
Injection-based liquid process, PolyJet
Nämn 2-3 fördelar modellfräsen har jämfört med 3D printer?
Large freedom to choose material
Excellent dimensional control
Good surface contro