A new surface error calculation method for layered manufacturing processes is proposed in this paper. The developed method is used to generate the layers by adaptively varying the thickness of the layers based on the surface approximation errors. Traditionally, the surface errors are calculated using local approximation techniques. In this paper, the surface approximation errors are calculated more accurately by marching through the surface points and determining the distances between layers and the surface points. Using the calculated distances, the adaptive layers are generated for both traditional two‐dimensional layer and ruled‐layer approximation methods. It has been shown that layered manufacturing (rapid prototyping) processes can achieve better accuracy and efficiency using the proposed surface error calculation and the adaptive ruled layer approximation methods. Computer implementation and illustrative examples are also presented in this paper.
Rapid Prototyping Journal – Emerald Publishing
Published: Dec 1, 2004
Keywords: Rapid prototypes; Approximation theory; Error analysis