Performance Evaluation of Various STL File Mesh Refining Algorithms Applied for FDM-RP Process

Layered manufacturing machines use the stereolithography (STL) file to build parts. When a curved surface is converted from a computer aided design (CAD) file to STL, it results in a geometrical distortion and chordal error. Parts manufactured with this file, might not satisfy geometric dimensioning and tolerance requirements due to approximated geometry. Current algorithms built in CAD packages have export options to globally reduce this distortion, which leads to an increase in the file size and pre-processing time. In this work, different mesh subdivision algorithms are applied on STL file of a complex geometric features using MeshLab software. The mesh subdivision algorithms considered in this work are modified butterfly subdivision technique, loops sub division technique and general triangular midpoint sub division technique. A comparative study is made with respect to volume and the build time using the above techniques. It is found that triangular midpoint sub division algorithm is more suitable for the geometry under consideration. Only the wheel cap part is then manufactured on Stratasys MOJO FDM machine. The surface roughness of the part is measured on Talysurf surface roughness tester.