Multi-Axis High Speed Milling : How to Speed up Prototyping & Tooling Processes by Using STL-Technology

Despite the wide application of Layered Manufacturing Technologies like fused Depositîon Modelling, Layered Object Manufacturing etc. in the product development process, mihing is stil necessary. This is because Layered Manufactunng processes have some Iimitatïons in for instance, materials used and sizes of products that can be made. In these cases the milling process must be applied, but in a way that rîght-first-time and speed is guaranteed, otherwise the job is no Jonger rapid. The introduction of 3D CAD/CAM was a step forward. Nevertheless, some problems occur in this 3D CADIcAM process, such as the reliability of transfer of geometdcal data from a CAD-system to a CAM system, the calculatïon speed and reliabilïty of the generated milling paths, and the complexity (in both a technical and orginazational way) of the mil]ing process itself. By identifying the fundamental causes of these problems it was possible to look for new ways to come to a fast and right first-time approach for the 3D CAD/CAM milling process. By combining reliable STL files with the 3D CAD-CAM milling process a reliable, fast, and easy to use process now becomes available. This paper describes the problems that occured in the 3D CADCAM milling proces from a users point of view, the causes for these problems, and the way in which STL technology can solve these problems. It will also describe experiences, results, and industrial applications in the Prototyping and Tooling area of the product development process hy using 3D CAD/CAM mïlling in combination with STL technology This is done to show that there are fast methods available for using milling processes in Rapid Protoyping and Tooling projects.