A Prototype Two-Axis Laser Scanning System used in Stereolithography Apparatus with New Algorithms for Computerized Model Slicing

Problem statement: A successful operation of rapid prototyping process depends on software and hardware which are used in RP machines. About software, an efficient technique is required to slice the CAD model. Several slicing methods are used for slicing from Standard Triangulation Language (STL) files, such as direct slicing and adaptive slicing. Using these methods reduce accuracy of physical part or increase process time. About hardware, in Stereolithography (SLA) apparatus, two mirrors have been used to reflect laser beam. Approach: In this study new algorithms were developed for part slicing from STL file and modifying the laser beam path such as: Derivation of contours in each layer, generate contour family tree, detective arcs and modifying laser beam path. A modified mechanism was designed and developed based on only one mirror to reflect laser beam. Results: These algorithms were used in a visual basic interface and the developed mechanism was implemented in a prototype apparatus. Conclusion: Developed algorithms decreased CAD model slicing time and generated more accurate laser beam path than usual methods and fabricated apparatus decreased scanning mechanism complexity and volume of the scanning system.