NON-PLANAR TOOLPATH FOR LARGE SCALE ADDITIVE MANUFACTURING

Year 2021, , 477 - 487, 30.12.2021

Ömer Eyercioğlu , Mehmet Aladağ

https://doi.org/10.46519/ij3dptdi.956313

Cited By: 2

Abstract

The parts produced by additive manufacturing are inherently subjected to discretization effects due to their layer-based addition. The stair-stepping effect on the surface quality is inevitable for most of the techniques and it becomes more dominant for the regions having small surface inclinations. The stair-stepping influences the mechanical properties as well as the aesthetic perception. Many researchers have been presented several approaches to overcome or minimize the stair-stepping effects and improve the surface quality of additively manufactured parts. The attempts have been made generally for the FDM-printed objects, however, there is no or fewer efforts have been made for parts of large-scale additive manufacturing (LSAM). Due to higher deposition rates (up to 50 kg/hrs.) and larger nozzle diameters (i.e. bead size) the discretization effect is more in large-scale additive manufacturing. In this paper, the presented methods to mitigate the stair-stepping effect and improving the surface quality of additive manufacturing are reviewed and practicing in large-scale 3D printing is discussed. A preliminary experimental study of 3D printing with a non-planar toolpath was carried out and the results were presented.

Keywords

Large scale additive manufacturing (LSAM), non-planar 3D printing, stair-stepping effect, surface quality

References

• 1. Chen L., Chung M.F., Tian Y., Joneja A., Tang K., "Variable-depth curved layer fused deposition modeling of thin-shells", Robotics and Computer-Integrated Manufacturing, Vol. 57, Issue January, 2019.
• 2. Mohan Pandey P., Venkata Reddy N., Dhande S.G., "Slicing procedures in layered manufacturing: A review", Rapid Prototyping Journal, Vol. 9, Issue 5, 2003.
• 3. Pelzer L., Hopmann C., "Additive manufacturing of non-planar layers with variable layer height", Additive Manufacturing, Vol. 37, Issue May 2020, 2021.
• 4. Gosselin C., Duballet R., Roux P., Gaudillière N., Dirrenberger J., Morel P., "Large-scale 3D printing of ultra-high performance concrete - a new processing route for architects and builders", Materials and Design, Vol. 100, 2016.
• 5. Micali M.K., Dornfeld D., "Fully three-dimensional toolpath generation for point-based additive manufacturing systems", Solid Freeform Fabrication 2016: Proceedings of the 27th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2016, 2016.
• 6. Ahlers D., "3D printing of nonplanar layers for smooth surface generation", University of Hamburg, 2018.
• 7. Allum J., Kitzinger J., Li Y., Silberschmidt V. V., Gleadall A., "ZigZagZ: Improving mechanical performance in extrusion additive manufacturing by nonplanar toolpaths", Additive Manufacturing, Vol. 38, Issue November 2020, 2021.
• 8. Xu J., Sheng H., Zhang S., Tan J., Deng J., "Surface accuracy optimization of mechanical parts with multiple circular holes for additive manufacturing based on triangular fuzzy number", Frontiers of Mechanical Engineering, 2021.
• 9. Khurana J.B., Dinda S., Simpson T.W., "Active - Z printing: A new approach to increasing3D printed part strength", Solid Freeform Fabrication 2017: Proceedings of the 28th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2017, 2020.
• 10. Es-Said O.S., Foyos J., Noorani R., Mendelson M., Marloth R., Pregger B.A., "Effect of layer orientation on mechanical properties of rapid prototyped samples", Materials and Manufacturing Processes, Vol. 15, Issue 1, 2000.
• 11. Feng X., Cui B., Liu Y., Li L., Shi X., Zhang X., "Curved-layered material extrusion modeling for thin-walled parts by a 5-axis machine", Rapid Prototyping Journal, Vol. 27, Issue 7, 2021.
• 12. Tyberg J., Bohn J.H., "Local adaptive slicing for Layered Manufacturing", Rapid Prototyping Journal, Vol. 4, Issue 3, 1998.
• 13. Sabourin E., Houser S.A., Bøhn J.H., "Adaptive slicing using stepwise uniform refinement", Rapid Prototyping Journal, Vol. 2, Issue 4, 1996.
• 14. Zhou M.Y., Xi J.T., Yan J.Q., "Adaptive direct slicing with non-uniform cusp heights for rapid prototyping", International Journal of Advanced Manufacturing Technology, Vol. 23, Issue 1–2, 2004.
• 15. Cormier D., Unnanon K., Sanii E., "Specifying non-uniform cusp heights as a potential aid for adaptive slicing", Rapid Prototyping Journal, Vol. 6, Issue 3, 2000.
• 16. Huang B., Singamneni S., "A mixed-layer approach combining both flat and curved layer slicing for fused deposition modelling", Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 229, Issue 12, 2015.
• 17. Mohan Pandey P., Venkata Reddy N., Dhande S.G., "Slicing procedures in layered manufacturing: A review", Rapid Prototyping Journal, Vol. 9, Issue 5, 2003.
• 18. Chakraborty D., Aneesh Reddy B., Roy Choudhury A., "Extruder path generation for Curved Layer Fused Deposition Modeling", CAD Computer Aided Design, Vol. 40, Issue 2, 2008.
• 19. Cendrero A.M., Fortunato G.M., Munoz-Guijosa J.M., De Maria C., Díaz Lantada A., "Benefits of Non-Planar Printing Strategies Towards Eco-Efficient 3D Printing", Sustainability, Vol. 13, Issue 4, 2021.
• 20. Zhao H. ming, He Y., Fu J. zhong, Qiu J. jiang, "Inclined layer printing for fused deposition modeling without assisted supporting structure", Robotics and Computer-Integrated Manufacturing, Vol. 51, 2018.
• 21. D. D., Pan Z., D. Cuiuri H. L., N. L., S. van D., "Multi-Direction Slicing of STL Models for Robotic Wire-Feed Additive Manufacturing", in International Solid Freeform Fabrication Symposium, Pages 1059–1069, 2015.
• 22. Llewellyn-Jones T., Allen R., Trask R., "Curved Layer Fused Filament Fabrication Using Automated Toolpath Generation", 3D Printing and Additive Manufacturing, Vol. 3, Issue 4, 2016.
• 23. Diegel O., Singamneni S., Huang B., Gibson I., "Getting rid of the wires: Curved layer fused deposition modeling in conductive polymer additive manufacturing", Key Engineering Materials, Vol. 467–469, 2011.
• 24. Singamneni S., Roychoudhury A., Diegel O., Huang B., "Modeling and evaluation of curved layer fused deposition", Journal of Materials Processing Technology, Vol. 212, Issue 1, 2012.
• 25. Huang B., Singamneni S., "Curved layer fused deposition modeling with varying raster orientations", Applied Mechanics and Materials, Vol. 446–447, 2014.
• 26. Huang B., Singamneni S., Diegel O., "Construction of a curved layer rapid prototyping system: Integrating mechanical, electronic and software engineering", 15th International Conference on Mechatronics and Machine Vision in Practice, M2VIP’08, 2008.
• 27. Shembekar A. V., Yoon Y.J., Kanyuck A., Gupta S.K., "Trajectory planning for conformal 3D printing using non-planar layers", Proceedings of the ASME Design Engineering Technical Conference, Vol. 1A-2018, 2018.
• 28. Allen R.J.A., Trask R.S., "An experimental demonstration of effective Curved Layer Fused Filament Fabrication utilising a parallel deposition robot", Additive Manufacturing, Vol. 8, 2015.
• 29. Jin Y., Du J., He Y., Fu G., "Modeling and process planning for curved layer fused deposition", International Journal of Advanced Manufacturing Technology, Vol. 91, Issue 1–4, 2017.
• 30. De Jager P.J., Broek J.J., Vergeest J.S.M., "Using adaptive ruled layers for Rapid Prototyping: principles and first results", Solid Freeform Fabrication Symposium Proceedings, 1996.
• 31. Hope R.L., Roth R.N., Jacobs P.A., "Adaptive slicing with sloping layer surfaces", Rapid Prototyping Journal, Vol. 3, Issue 3, 1997.
• 32. Hope R.L., Jacobs P.A., Roth R.N., "Rapid prototyping with sloping surfaces", Rapid Prototyping Journal, Vol. 3, Issue 1, 1997.
• 33. Thomas C.L., Gaffney T.M., Kaza S., Lee C.H., "Rapid prototyping of large scale aerospace structures", in IEEE Aerospace Applications Conference Proceedings, Vol. 4, Pages 219–229, 1996.
• 34. Ahlers D., Wasserfall F., Hendrich N., Zhang J., "3D printing of nonplanar layers for smooth surface generation", IEEE International Conference on Automation Science and Engineering, Vol. 2019-Augus, Issue September, 2019.
• 35. Liu S., Joneja A., Tang K., "A new adaptive slicing algorithm based on slice contour reconstruction in layered manufacturing process", Computer-Aided Design and Applications, Vol. 18, Issue 6, 2021.
• 36. Eyercioglu O., Aladag M., Sever S., "Temperature Evaluation and Bounding Quality of Large Scale Additive Manufacturing Thin Wall Parts", Sigma J Eng & Nat Sci, Vol. 36, Issue 3, 2018.
• 37. "Slic3r - Open source 3D printing toolbox". https://slic3r.org/, April 7, 2021.
• 38. "GitHub - DrEricEbert/Slic3r_NonPlanar_Slicing: Slic3r with integrated electronics and Nonplanar slicer (see branches)". https://github.com/DrEricEbert/Slic3r_NonPlanar_Slicing, April 7, 2021.
• 39. Eyercioglu O., Aladag M., Aksoy A., Gov K., "Determination of The Maximum Bridging Distance in Large Scale Additive Manufacturing", in 4th International Congress on 3d Printing (Additive Manufacturing) Technologies and Digital Industry, Pages 40–48, 2019.
• 40. Zhao G., Ma G., Feng J., Xiao W., "Nonplanar slicing and path generation methods for robotic additive manufacturing", International Journal of Advanced Manufacturing Technology, Vol. 96, Issue 9–12, 2018.
• 41. Xie F., Chen L., Li Z., Tang K., "Path smoothing and feed rate planning for robotic curved layer additive manufacturing", Robotics and Computer-Integrated Manufacturing, Vol. 65, 2020.
• 42. Shan Y., Gan D., Mao H., "Curved Layer Slicing based on Isothermal Surface", Procedia Manufacturing, Vol. 53, 2021.