This paper discusses the effect of geometric shape on the accuracy of direct metal laser sintering (DMLS) prototypes. The percentage shrinkages due to different shapes are investigated and their empirical relationship is determined. A new speed-compensation (SC) method is proposed to reduce uneven shrinkage affected by the two-dimensional geometric shape at each layer. From case studies conducted, the optimized SC method is found to be efficient in improving the accuracy of prototypes fabricated. Note to Practitioners-This paper aims to address the problem of dimensional errors of parts built by the direct metal laser sintering (DMLS) process. Existing compensation approaches are normally based on a general relationship between the nominal dimensions and the errors after sintering. However, the effect arising from different geometric shapes is not considered. A new approach is proposed using different scan speed settings to compensate for the effect of geometric shapes to improve the dimensional accuracy of the entire part. During processing, the laser sinters along the trajectory are guided by the hatch vectors or dexel. An appropriate experimental method is used to establish the relationship for different scan speeds with the dexel length to the final accuracy. When building the part, the laser scan speed is adjusted dynamically according to the dexel length which varies with the geometric shape of the part. The case study demonstrates that the proposed method can generate correct speed settings to effectively increase the dimensional accuracy of the final part. Although this method has been developed based on the DMLS process, it is also applicable to other laser sintering processes. In future research, other process parameters, such as laser power, will be considered independently, or together with the scan speed, for possible further improvement on the dimensional accuracy.

The factors that generally affect the slicing error in layered manufacturing (LM) processes are first analyzed, and issues pertaining to the current methods to deal with the slicing error are discussed in this paper. A method based on a recently developed and implemented orthogonal LM system to reduce the overall slicing error is presented. In this method, the flat region is separated from the stereolithography (STL) model and different processing methods are applied to the different areas in the part geometry. In addition, the mathematical model for calculating the slicing error is derived and an approach based on a genetic algorithm has been developed to optimize the build orientation in terms of minimizing the slicing error. Case studies are given to demonstrate the effectiveness and efficiency of the method. Note to Practitioner-The staircase effect has been the major concern for industry to widely adopt rapid prototyping technologies. It will not only worsen the surface quality but also create errors on the parts built. This paper introduces a novel approach to minimizing staircase errors based on a multidirectional deposition approach. A mathematical method combined with a generic algorithm is used to minimize the slicing errors. From the case study given, the approach has been proven to be effective in minimizing staircase errors and thus improving the rapid prototyping (RP) built part quality.

In this paper, a probabilistic design approach is presented to evaluate the reliability of piezoelectric micro actuators. Based on the relationship between the lifetime, and degradation mechanism of piezoelectric actuators, and the electric field strength, the concept of "electric strength" is proposed to indicate the electric field strength of the piezoelectric actuators at a specified lifetime. The lifetime (number of cycles to failure) of the piezoelectric actuator, electric strength, and electric load are considered as the random variables; and their probability distributions are discussed. The interference model of electric load, and electric strength is introduced to the reliability design of piezoelectric micro actuators. By this approach, the relationship between the reliability, and the lifetime of the piezoelectric actuator can be given. A case study of the disk drive head positioning system demonstrates the application of the approach.

The effect of a repair of a complex system can usually be approximated by the following two types: minimal repair for which the system is restored to its functioning state with minimum effort, or perfect repair for which the system is replaced or repaired to a good-as-new state. When both types of repair are possible, an important problem is to determine the repair policy; that is, the type of repair which should be carried out after a failure. In this paper, an optimal allocation problem is studied for a monotonic failure rate repairable system under some resource constraints. In the first model, the numbers of minimal & perfect repairs are fixed, and the optimal repair policy maximizing the expected system lifetime is studied. In the second model, the total amount of repair resource is fixed, and the costs of each minimal & perfect repair are assumed to be known. The optimal allocation algorithm is derived in this case. Two numerical examples are shown to illustrate the procedures.

Path generation is an important factor that affects the quality and efficiency of most layered manufacturing processes such as SLS, SLA and FDM. This paper introduces an efficient path generation algorithm. The principle of the algorithm and the implementation are presented. A comparative study is used to analyze the effectiveness of this method. The results of comparison on both the path length and processing time between the traditional method and the proposed method are discussed.