Segmentation of Dimensionally-Large Rapid Prototyping Objects

Abstract

An algorithm was developed to enable efficient segmentation of dimensionally-large objects into smaller components that can be fabricated within the given Rapid Prototyping (RP) machine workspace. The algorithm uses vertical and horizontal flat plane cuts, as well as feature-based volume decomposition. Due considerations were given to the optimisation of the surface accuracy, the build time, the strength and the number of segments generated by the segmentation process. A computer-aided design (CAD) application programme that interfaces with Unigraphics (UG) was also developed to allow import of objects in Standard Triangulated Language (STL) files into UG without loss of accuracy. In addition, the application software provides the functions that facilitate the implementation of the segmentation algorithm in UG. Two case studies were carried out using the algorithm in a Selective Laser Sintering (SLS) RP system. The resulting objects had properties that matched the research objectives with which the proposed algorithm was validated.