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One
field of Advanced Manufacturing is Layered Manufacturing, in which parts
are built through layered deposition of semi-liquid material. Layered Manufacturing
can build parts of virtually any shape without involving any cutting or
assembly; something traditional manufacturing cannot do.
The Process
of building the part by Layered Manufacturing can be divided into following
stages:
1. Modeling
- A three-dimensional model of the part is designed using Computer-Aided
Design (CAD) Software, such as I-DEAS, Autocad,ProEngineer, or other similar
programs.
2. Slice Generation - The CAD model of the part is represented
as a set of layers by "slicing" it with the set of equally-spaced
horizontal planes. The distance between planes is called "layer thickness".
3. Toolpath Generation - Each two-dimensional layer is "filled"
by the set of lines called "toolpath". Stages 2 and 3 are performed
using specialized software, such as QuickSlice.
4. Deposition - The toolpath is loaded into the Layered Manufacturing
machine, and the part is built by depositing the material along the toolpath.
Usually, the material is a ceramic or wax "filament", which
is pushed through the liquefier by the rollers. Material melts inside
the liquefier and comes out as a viscous "paste" with a certain
flow rate. Each layer is built by moving the liquefier along the toolpath
while depositing the material into the horizontal "table". When
the layer is finished, the "table" shifts down, and the next
layer is started.
5. Post-processing - Depending on the material or the part, some
processing may be performed after the part is built. For example, a ceramic
part may be sintered and polished.
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