High Speed Milling : By using STL-Technology

Despite the wide application of Layered Manufacturing Technologies like Fused Deposition Modelling, Layered Object Manufacturing etc. in the product development processes, milling is stili necessary. This is a result of the fact that Layered Manufacturing processes have some limitations 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 first-time-right and speed is guaranteed. Otherwise the job is not rapid anymore. The introduction of 3D CAD-CAM was a step forward. Nevertheless some problems occur in this 3D CAD-CAM process. Such as the reliability of transfer of geometrical data from CAD-system to CAM-system, the calculation speed and reliability of the generated milling paths and the complexity (in both technical and orginazational way) of the milling process itself. By identifying the fundamental causes of these problems it was possible to look for new ways to come to a fast and first-time-right approach for the 3D CAD-CAM milling process. By combining the reliable STL-files with the 3D CAD-CAM milling process a reliable, fast and easy to use process now becomes available. This paper describes from a users point of view the problems that occured in the 3D CAD CAM milling proces, the causes for these problems and the way in which the STL Technology can solve these problems. It will also describe experiences, resuits and industrial applications in the Prototyping and Tooling area of the product development process by using 3D CAD-CAM milling in combination with STL-Technology. This is done to show that there are fast methods available to use the milling processes in Rapid Protoyping and Tooling projects.