Virtual Simulation for Multi-material LM Process

In an ONR funded MURI program, to improve quality of multi-material parts, we've been developing an advanced computer simulation for the multi-material layered manufacturing (LM) process. The CAD models and their .stLfiles are created using. the commercially available software such as I-DEAS and ProE. Using this information, one tool path file per material is generated. Our file preparation algorithm, systematically, layer by layer, integrates all tool path files into one multi-material tool path file. The results of the multi-material tool path are graphically visualized using the simulation algorithm (written in c++ & SGI OpenGL). From a virtual simulation, we can check the LM process, and make the best selection of tool path parameters afterwards. After several trials from design to simulation, if the simulation result is acceptable, the real manufacturing can be started. And the part's quality should be better than a part manufactured without running simulation in advance. This paper will represent .•. new studies on using real toadshapes to get more realistic simulation results. Many parts have been successfully simulated using our method.