Abstract: Physical model recovered from cloud dada only with coordinate information is of great importance in the integration of reverse engineering and rapid prototyping technology. A new method, that rapidly generates prototype from sampled points, is proposed. Based on establishing the spatial partitioning representation of point cloud, the contour data in each layer is firstly calculated and sequenced, then amended to generate exact slice file. It overcomes lots of drawbacks in traditional integration such as consuming time and needing expert modeling skills. Moreover, without the intermediate transactions of STL file, the work of checking and repairing mistakes of facets is avoided. It is very suitable for laminated object anufacturing and greatly improves the pretreatment efficiency of RP technology.

Key words: Direct slicing Rapid prototyping, Reverse engineering Data cloud, 5A06 aluminum alloy, hydro-bulging, limited bulging height, stress- strain, double-layer sheets