ADDITIVE MANUFACTURING TECHNOLOGIES

UNIT 4
PART-B
Rapid Prototyping Software
1.0Magics Software
Over the past few years, Magics RP software has proven to be an indispensable software tool for
achieving the goal. This delivers high quality prototypes with the shortest lead times. At the
same time, Magics provides with full documentation of the process.
Magics RP software can import most standard 3D formats - STL, VDA, IGES, STEP, VRML -
and native CAD formats like UG/Para solid and CATIA. It can also work with scanned data by
offering the import and export of point clouds.
The imported files are converted to a digital CAD structure according to a user-defined accuracy.
The conversion process includes correction of common errors. The resulting STL file is ready to
produce prototypes or tools without the need for further conversion.

1.1 Features of Magics Software:

Magics software calculates a comprehensive quote in seconds:
Magics software has excellent 3D visualization capabilities, instantly giving a clear picture of a
part's intricacies. With Magics build time estimator, the machine capacity and cost can be
assessed. Simply input the necessary dependencies, such as volume or surface, and the software
will define the parameters for calculating the cost of a part.
Magics software cuts back repair time for STL files:
Since CAD systems don't always export clean STL files, correction may be needed before they
can be sent to an RP machine. Magics software is packed with features that interact directly on
defective files and correcting errors in a matter of minutes.
Magics software allows process-related design changes:
Magics software includes several critical features specifically developed to optimize the process.
Examples:
 Compensate for parts that need to be milled or painted after production by offsetting
them.
 Hollow the parts to avoid deformation as a result of internal stresses and to save on
material.
  Pinpoint the best way to cut large parts to fit on the RP machine, ensuring a strong bond
when they're glued together later.
 Put indicators into position to determine the best possible location for a seam, and for
simpler assembly.
 Label the parts so that they're easier to identify.
 Other features such as removing holes, Boolean operations, triangle reduction, triangle
smoothing and aligning.
Magics software speeds up specialized RP work preparation:
Magics can save time on data pre-processing. Parts can be nested with a single mouse-click.
Magics' powerful nesting function quickly arranges the parts on the smallest possible area.
Magics slices the STL file into the desired format in just a few seconds. Magics takes care of the
final step too, automatically generating the necessary supports before sending the STL to a
stereolithography machine.
Magics software provides unmatched quality control:
The Magics Rapid Fit module offers a fast, unique solution for quality control. Create fixtures in
three easy steps: position the part on the reference plate, indicate on the part the contact points
that need fixtures, and Magics will design the fixtures automatically, based on customized
settings. The fixtures can be built on an RP machine simultaneously with the part.
Magics software offers detailed documentation:
Not only does Magics prepare data for RP machines, it also creates documents that can guide the
overall product flow, from quotation through production to quality control.
The templates provide the freedom to document a part with the information to be included. Once
the template is defined, Magics uses the part information to generate specifications automatically
into a document. Use these standardized documents to provide a client with a quote, to guide the
finishing on the shop floor, and for quality control.

2.0 Mimics Software:

The MIMICS software takes care of medical image processing, and is capable of converting CT
and MRI data directly to Rapid Prototyping models. Additional modules are available for
medical device design or dental implant preparation.
Mimics interfaces between scanner data (CT, MRI, Technical scanner,) and Rapid prototyping,
CAD or Finite Element analysis. The Mimics software is an image processing package with 3D
visualization functions that interfaces with all common scanner formats.
2.1 The applications of Mimics:
Although Mimics was originally designed to link medical images to rapid prototyping, there are
many applications possible using the 3D model. The applications are:
 Rapid Prototyping (RP)
 Computer Aided Engineering (CAE)
 Computer Aided Design (CAD)
 Surgical Simulation
All these applications require slightly different processing before they can effectively be used.
Mimics Remesher
Mimics Remesher provides 14 of the most common quality inspection parameters.
Easy automatic remeshing:
The Remesher can improve mesh quality automatically. The software searches for all triangles
whose quality is below the indicated level and transform them to triangles with a better shape.
Manual remeshing:
In some cases, a few triangles with a shape inferior to the required quality level may remain after
automatic remeshing. The Remesher offers a unique toolbox to reshape those triangles manually.
Increased reliability and accuracy of FE analyses:
The Mimics Remesher is a highly automated interface with FEA packages. It significantly
increases the reliability and accuracy of FEA results on STL models. Most FE packages don't
allow to manipulate or optimize the mesh generated when a part is imported. This might reduce
the accuracy of the results. With the Remesher, the file can be optimized and deliver good
meshes that will run in the FEA software.
Reduced calculation times:
Calculation times for running a sub-optimal mesh can be very lengthy. The optimized meshes
generated by the Remesher usually take a much shorter time.

3.0 SolidView Software:

Solid View software allows non-CAD users to easily view, measure and markup CAD data,
opening up communication to all who need to be involved in the design process.
3.1 SolidView Features:
View – Measure – Markup CAD Data:
SolidView’s advanced feature recognition capabilities combined with its extensive measurement
options make it possible to measure any design feature or attribute. This means that engineers
don’t need to spend hours creating complex 2D drawings just in case someone needs a particular
dimension. One mouse click will instantly calculate volume, surface area, mass and center of
gravity for complex designs and assemblies. Annotation features make it easy to communicate
design intent or to highlight changes or errors. Note and text features add detailed design
information, and an electronic grease pencil add red-line markups.
Supports Popular CAD Formats:
It supports popular CAD formats such as SolidWorks, Pro/E, CATIA, Unigraphics, IGES, STEP
and many others. It is also possible to import geometry from multiple CAD systems into one
SolidView file.
CAD Interaction for Non-CAD Users with SolidView:
Unlike complex CAD systems, SolidView is easy to learn, use and re-learn. No formal training is
required and online video tutorials are available
Applications of SolidView:
 Design Reviews
 Assembly Instructions
 Design Collaboration
 Manufacturing Quotes
 RP Layout and Repair
 Project Management
 Request for Quote/Proposal
 Shop Floor
 Technical Illustrations
 Communication and Visualization

4.0 View Expert Software:

ViewExpert is entry level tool targeted for viewing, verifying, dimensioning and communicating
3D geometry information. View Expert allows to input triangle models, create consistent
topology, check errors, repair normal's and output STL data for 3D printing without any cost.
For validating 3D model data:
 View Expert is a software tool for CAD designers to provide perfect solid data to
downstream applications.
 Import STL models or optionally surface models into View Expert.
 Locate costly errors and correct them.
 Verify the integrity of the data before sending it to rapid prototyping, CNC or CAE
systems.
View, verify and communicate faceted 3D models:
ViewExpert can input and output all relevant faceted 3D file formats for Additive
Manufacturing. Automatic model verification, measuring and clipping commands help to easily
decide if the model can be printed or not.
 Input various faceted models: STL, VRML, ZPR, OBJ, DXF, PLY, 3DS, Collada, FBX
and proprietary 3DE Files.
 Output following faceted models: STL, VRML, ZPR, DXF, PLY and 3DE Files.
 Automatically orient triangle normal direction for correct 3D Printing.
 Viewing with rotate, pan, zoom and clipping commands, real-time slices for internal
geometry checking.
 Measuring with distance, radius, angle, wall thickness and 2D Drawings commands.
 Export bounding box, area and volume for build time estimation
4.1 ViewExpert offers the following features:
ViewExpert for STL files
 Faster display list generation and texture handling
 Improved topology generation for architectural models
 64 bit implementation improvements to handle millions of triangles
Communication
 Print and Email Images and 3D Geometry with Annotations and Measures
 Input STL, VRML, ZPR, OBJ, DXF, PLY, 3DS, Collada, FBX and 3DE Files
 Write STL, VRML, ZPR, PLY and 3DE Files
Model Editing
 Cut, Copy and Paste 3D Data
 Help Text window to Aid in the Analysis Process
 Different Error Filtering Levels for Repairing Models for Simulation vs. 3D Printing
3D Viewing, Transformations and Measuring
  Viewing with Colors, Textures and Clipping
 Transformations to Scale, Position, Rotate, Mirror & Platform positioning
 Generate professional 2D Drawings from STL data
 Point value, Distances, Angle, Radius and Wall Thickness Measuring
5.0 Rhino Software:
STL is the standard format for rapid prototyping systems. While STL was originally developed
for use with stereolithography, many other processes now use it. Since SLA machines usually
require the STL file to be a watertight mesh, Rhino provides tools for repairing mesh files to
remove gaps.
Using Rhino’s Bonus Tools, it is possible to print 3dm, STL, IGES, STEP, DWG, 3DS, and
many more file formats directly to a stereolithography printer or file. This allows taking nearly
any 3-D model and sending it to a prototyping machine. As with any model going to a printer,
the output STL file must be watertight. Rhino has many tools to repair STL files that are not
watertight and to create watertight geometry to send to a 3-D printer.
Rhino’s Bonus Tools includes commands for analyzing and repairing STL files to make them
watertight. There are new tools for advanced display, edge matching, selection, and filling holes.
These tools allow to manipulate meshes in ways previously not possible in Rhino. While Bonus
Tools mesh covers many new commands, the commands that are used for STL repair can be
grouped into a few categories:
• Offset (thicken)

• Display
• Remove unwanted detail
• Display and close gaps
5.1 Rhino Software has the following features:
 Display Mesh Wires
 Remove Unwanted Detail
 Display Gaps
 Close Gaps
 Stitch Larger Gaps
 Fill Holes
 Remove Geometry by Feature
 Fill Holes between Objects

6.0 3D-DOCTOR
3D-DOCTOR Software is used to extract information from image files to create 3D model. It is
developed by Able Software Corp. It is an advanced 3D modeling, image processing and
measurement software for MRI, CT, PET, microscopy, scientific, and industrial imaging
applications.
3D-DOCTOR's vector-based tools support easy image data handling, measurement, and analysis.
3D CT/MRI images can be re-sliced easily along an arbitrary axis. Multi-modality images can be
registered to create image fusions. Misaligned slices can be automatically or semi-automatically
aligned using 3D-DOCTOR's image alignment functions. Other image processing functions
include template-based film cropping, image re-slicing to correct slices of uneven thickness,
volume resizing, and image rotation.

3D-DOCTOR supports a variety of image formats in both 2D and 3D. These formats include
DICOM, TIFF, JPEG, BMP, Interfile, GIF, PNG and RAW. Other non-standard image formats
are also supported, but only with known dimensions (number of columns, rows and planes), bit
depth per pixel, little endian or big endian, and the size of file header.

3D-DOCTOR supports both grayscale and color images stored in DICOM, TIFF, Interfile, GIF,
JPEG, PNG, BMP, PGM, RAW or other image file formats. 3D-DOCTOR creates 3D surface
models and volume rendering from 2D cross-section images in real time.
Using 3D doctor, it is possible to export the polygonal mesh models to STL, DXF, IGES, 3DS,
OBJ, VRML, XYZ and other formats for surgical planning, simulation, quantitative analysis and
rapid prototyping applications. Leading hospitals, medical schools and research organizations
around the world are currently using 3D-DOCTOR.

Features of 3D Doctor Software

 Unique vector-based technologies for better 3D model creation and easy editing.
 Surface model uses smaller number of triangles while maintaining all details for high
quality rapid prototyping applications.
 Smart memory management with no limit for the number of slices to be used. It has
been used to process images with over 2000 slices on a PC with only 256MB RAM.
 Single command volume calculation and quantitative analysis report
 Handles DICOM and other image formats, such as TIFF, JPEG, PNG, GIF, BMP,
Interfile and RAW (vendor proprietary formats).
 Works with both grayscale and color images (color classification and separation)
 Supports CT, MRI, PET, microscopy, industrial CT, scanned film images, boundary
slices, slice data and XYZ points.
 High End 3D Image Processing Functions: image registration for multi-modality
application, image fusion, image resizing, image reslicing, etc.
  3D Output Formats: STL (ASCII and Binary), VRML, DXF, 3D Studio, IGES,
Wavefront OBJ and more.
 Software Reliability: No known bugs in our products because we fix them right away
once they are reported.
 Reasonably priced.
7.0 Materialise 3-Matic
Materialise introduced its 3-matic software, allowing 3D printer users to edit files directly in the
STL format. Previously, if design changes were required in the digital model, designers had to
make them in the CAD suite of choice before re-converting the entire file to STL again. 3-matic
enables design optimization and modification on STL level, using CAD designs, scanned data
and topology optimized models as a starting point. It allows 3D printer users to edit files directly
in the STL format.

Design with Materialise 3-matic will:

 Modify design at mesh level

 Create textures, patterns and perforations

 Create latticed, conformal or porous structures

 Clean up rough topology optimization results for simulation (FEA) and printing

 Convert mesh back to CAD

Features

 Enjoy freedom of design, create a unique or customized object

 Control density with latticed, conformal and porous structures

 Save material, reduce printing time and decrease costs with lightweight designs

 Change aerodynamic, acoustic and cushioning properties or increase grip

 Avoid labor-intensive finishing steps with smart use of textures

 Gain foresight from the strong link with simulation packages

 Automate your design process or accelerate your iteration cycles, by scripting these flows
using the 3-matic Python API
8.0 3Data Expert
3Data Expert is a professional tool for preparing 3D models for Additive Manufacturing and
Simulation applications.
3Data Expert includes commands for manipulation of both 3D surface models and 3D faceted
models. These commands include surface triangulation, STL verification and repair, STL
offsetting, splitting, connecting, decimation, smoothing, shrink wrap, 3D nesting and Boolean as
well as STL coloring and texturing. Sand Supports can be generated for delicate sand parts.
Basic supports can be generated for Stereolithography process. 3Data Expert® is supported on
Windows XP / Vista / 7 / 8 / 8.1 / 10.
8.1Functions
Repair faceted 3D models
3Data Expert offers effective and user friendly repair tools for triangulated models. Models from
different CAD systems, with or without colors, can be effectively repaired using both automatic
and manual commands for Additive Manufacturing.
Split and connect large models
When the triangulated model is ready and repaired for AM processes, many times one problem
still remains. The model may not fit into to the build area of the 3D Printing process in use.
3Data Expert splitting and connection tools allow us to split and connect part halves accurately
after the build.
Automatic 3D nesting
3D nesting is used for positioning the parts of a model into a platform (workspace) in order to
send the model to a 3D printer
Create 3D Text and join geometries
Additive Manufacturing processes build several parts at once. Adding 3D Text will help to brand
a model or to tell apart the models when ready from the machine. With 3Data Expert 3D Text
mark-ups can be added to recognize parts from each other. Also, primitive and freeform
geometries can be generated for support or to add new features to the original part.
Advanced cutting functions
Medical and engineering processes may require very specific tools to cut models or to drill holes
for fixtures or connectors. Cut and Hole Tools available with 3Data Expert enable most delicate
Boolean operations with user defined surfaces even with complex model geometries.
Re-triangulate faceted models
3Data Experts fast triangle decimation and aspect ratio improving functions prepare 3D faceted
files for any simulation system effectively. Detailed user control over the reduction results
guarantee the optimal simulation result.
Add and save material, generate supports for AM
For flexible Additive Manufacturing operation final functions before part build may include
adding material or hollowing objects for faster build. Also, metal and stereolithography
processes may require supports for correct part build. 3Data Expert Print Preparation functions
offer the tools to give the finishing touches to the 3D models before manufacturing.
Paint and texture models
3Data Expert includes complete set of texturing and painting tools to prepared faceted models for
3D Color Printing.