CAD & REVERSE ENGINEERING

CAD
 Computer-aided design (CAD) involves creating
computer models defined by geometrical
parameters.
 Three-dimensional representation of a part or a
system of parts, which can be readily altered by
changing relevant parameters
 CAD systems enable designers to view objects
under a wide variety of representations and to test
these objects by simulating real-world conditions.
Computer-aided manufacturing (CAM)

 Computer-aided manufacturing (CAM) uses

geometrical design data to control automated
machinery.
 CAM systems are associated with computer
numerical control (CNC) or direct numerical control
(DNC) systems.
 Computer-aided design and manufacturing systems
are commonly referred to as CAD/CAM.
Reverse Engineering Technology
 RE is the process of capturing geometric data from
object. This data is usually initially available in what
is termed “point cloud” form, meaning an
unconnected set of points representing the object
surfaces.
 These points need to be connected together using
RE software
Introduction - STL
 Additive manufacturing process that varies from
traditional manufacturing methodology is the
requirement to convert a CAD model into an STL
(stereolithography) file
 STL uses triangles (polygons) to describe the
surfaces of an object.
 There are several model limitations that should be
considered before converting a model to an STL file
including physical size, watertightness and polygon
count.
Introduction - STL
 The STL (Standard Triangle Language) is the
industry standard file type.
 CAD (Computer Aided Design) software allow you
to export their native file format into STL.
 The 3D model is then converted into machine
language (G-code) through a process called
“slicing” and is ready to print.
Step 1. Understand the STL resolution

 The STL file format uses a series of linked triangles

to recreate the surface geometry of a solid model.
 When you increase the resolution, more
triangles will be used, approximating the surfaces
of the 3D model better, but also increasing the
size of the STL file.
 There are two triangles per face. Since the cube has
six faces, it adds up to 12 triangles.
 Sphere ?
A sphere rendered in three different resolutions
Step 1. Understand the STL resolution

 If you export in too low of a resolution, the model

will have visible triangles on its surface when it is
printed
 Increasing the resolution above a certain point is
also not recommended, as it brings no additional
benefit
Step 2. Choose the right exporting parameters

 Resolution of your STL files by altering the tolerance

in your CAD software.
 Each CAD package has a different way of
specifying the STL resolution, but most use two main
parameters: chord height and angle.
 Step 2. Choose the right exporting parameters
 The chord height is the maximum distance that your software
will allow between the surface of the original 3D model and
the surface of the STL file.
 Using a smaller chord height will help represent more accurate
the curvature of a surface.
 The recommended value for the chord height is 1/20th of the
3D printing layer. It’s recommended to set the tolerance
between 0.01 millimeters and 0.001 millimeters
Errors in STL Files
STL File details
 The STL file format provides information about the
triangular facets that represent the object surface.
 Both ASCII encoding and binary encoding stores the
information of each triangle as:
 The coordinates of the vertices.
 The components of the unit normal vector to the
triangle. The normal vector should point outwards with
respect to the 3D model.
Rules for the STL File Format : The
Vertex Rule
 The vertex rule states that each triangle must share
two vertices with its neighboring triangles.
 Rules for the STL File Format : The Orientation Rule

 The orientation rule says that the orientation of the

facet must be specified in two ways.
 Direction of the normal should point outwards.
 The vertices are listed in counterclockwise order when
looking at the object from the outside (right-hand rule).

A software calculate the orientation from the normal and

subsequently from the vertices and
verify whether they match.

If it doesn’t, then it can declare the STL file to be corrupt!

 Rules for the STL File Format : The All
Positive Octant Rule
 This rule is to save space.
 If the 3D object were allowed
to live anywhere in the
coordinate space, we would
have to deal with negative
coordinates
 To store negative coordinates,
you use signed floating-point
numbers. Signed floating-point
numbers require one additional
bit to store the sign (+/-)
Coordinate values are represented as a floating-point number with exponent format
For example, “3.245000e-002”.
STL conversion and file manipulation

 Once a STL file has been generated the file is imported

into a slicer program. This program takes the STL file
and converts it into G-code. G-code is a numerical
control (NC) programming language.
 It is used in computer-aided manufacturing (CAM) to
control automated machine tools (including CNC
machines and 3D printers).
 The slicer program also allows the designer to customize
the build parameters including support, layer height,
and part orientation.
STL-based Slicing
 Uniform slicing generates constant layer thickness
slices.
 Adaptive slicing is a variant of the uniform slicing,
where the spacing between the slices is not constant
but determined by the geometry and machine
capability
Slicing Procedure
 The possibilities of intersection of a triangle facet
with a cutting plane can be categorized into the
five cases
Slicing Procedure
 (a) one vertex of facet on the cutting plane and the other
two on the same side, i.e., none of edges on the plane.
 (b) Two vertices of facet in the plane, i.e., one edge on the
plane.
 (c) One vertex in the plane, one above and one under, i.e.,
plane cutting through one vertex and its opposite edge.
 (d) The triangle facet on the plane, i.e., three vertices all in
the plane.
 (e) One vertex on one side and the other two on the other
side, i.e., plane cutting through two adjacent edges
Software pipeline from input STL to output G-code
GCcode
 ●The output of the slicer program is typically a
GCode file.
 ●GCode is used in many types of CNC machines.
(CNC = Computerized Numerical Control)
 ●Includes commands to move the extruder to
specified (x,y,z) coordinates, feed (or stop feeding)
plastic, etc
DATA PROCESSING FOR RAPID PROTOTYPING

 Data processing includes initial CAD modeling,

model conversion for data interfacing through an
STL file specification, part orientation
determination, support generation, and various
approaches for model slicing and tool path
generation.
 Data processing - largely affect the efficiency of
prototyping and part surface quality.
DATA PROCESSING
 CAD modeling
 computer-aided design (CAD) model of the object to
be fabricated
 solid model with complete topological and geometric
information.
 STL interfacing
 File format for defining an object using triangular
facets.
 Entire part geometry is converted into S TL format
based on a tolerance for accuracy control.
DATA PROCESSING
 Part orientation:
 specific orientation in which the prototype model to be
produced.
 Part accuracy, the amount of supporting material required
and ease of post-processing are important factors
influencing part orientation determination.
 Support generation:
 Define support structures for supporting down-facing areas
during part build-up
 Support generation can be done on the basis of a STL
model or the original CAD model.
DATA PROCESSING
 Model slicing and tool path generation :
 The Digital model of the object and related support
structures are sliced layer by layer.
 For each layer, a set of surface contours is obtained
and a tool path is defined within the material area for
model production in a layer-wise fashion
 Model production on a RP machine
 The produced tool path is sent to a RP machine for
building up the prototype model, including support,
layer by layer.
DATA PROCESSING
 Post-processing:
 Post-curing in the case of stereo lithography,
 infiltration and furnace sintering in the case of SLS,

 Removing the support structures and surface polishing in

the cases of most other RP processes.
Softwares for additive manufacturing technology

ASSIGNMENT :

MIMICS, MAGICS