Description:
<jats:sec><jats:title content-type="abstract-heading">Purpose</jats:title><jats:p>This paper presents an offset‐based tool path generation method for STL format three‐dimensional (3D) models. The created tool‐paths can be effectively used to near‐net‐shaped parts, in particular those created using rapid prototyping.</jats:p></jats:sec><jats:sec><jats:title content-type="abstract-heading">Design/methodology/approach</jats:title><jats:p>The STL model is first offset by the distance of the selected cutter radius using a unique 3D offset method. The intersections between the top facing triangles of the offset model and tool‐path drive planes are calculated. The intersection line segments are sorted, trimmed and linked to generate continuous top envelope curves, which represent interference‐free tool paths.</jats:p></jats:sec><jats:sec><jats:title content-type="abstract-heading">Findings</jats:title><jats:p>The developed offset‐based algorithm can rapidly and successfully generate interference‐free tool paths as continuous lines, instead of a collection of discrete tool location points. The strategy of using adaptive step‐over distances based on local geometrical information can significantly increase machining efficiency.</jats:p></jats:sec><jats:sec><jats:title content-type="abstract-heading">Research limitations/implications</jats:title><jats:p>The current tool path generation method only works for ball‐end mills. The entire surface of the STL model is treated as a single composite surface to be machined using raster milling. To improve machining efficiency, an automatic surface splitting algorithm could be developed to divide the model into several regions based on the characteristics of a group of triangular facets, and then machine these identified regions using different strategies and cutters.</jats:p></jats:sec><jats:sec><jats:title content-type="abstract-heading">Originality/value</jats:title><jats:p>The offset‐based tool‐path generation algorithm from STL models is a unique and novel development, which is useful in the rapid prototyping and computer‐aided machining areas.</jats:p></jats:sec>