Voxel-based virtual manufacturing simulation for three-dimensional printing

Abstract

This article presents a simulation program for previewing and emulating three-dimensional printing. The proposed simulator adopts a voxel-based virtual manufacturing approach to fabricate the target model in a virtual volume space. A mass-diffusion procedure coupling with adaptive filament deposition is used to generate the printing roads of the virtual manufacturing model. Thus, the resultant virtual model resembles the printed object better. As the virtual model has been built, the simulator performs line-drawing, animation and volume rendering to reveal the progression of the printing and the geometric features of the model, including its outer appearance, surface roughness and internal structures. Hence, more geometrical features of the model are shown. During the virtual manufacturing process, semantic error checking is also carried out to detect potential printing errors which may cause supporting problems, collisions, over- and under-extrusion, and other printing failures. Two efficient algorithms, using three rasters of voxels, are developed to conduct the kernel computations such that the run-time semantic error checking is simplified and the memory usage is reduced. Equipped with advanced modelling, debugging and graphics techniques, the proposed simulator can be used as a virtual three-dimensional printer as well as a debugger in additive manufacturing procedures. Users can utilize it to preview the resultant model and to evaluate the printing process such that potential errors can be prevented and the quality of the printed parts can be enhanced.