A method of additive manufacturing (AM) for the extrusion of material along three-dimensional curves is proposed as an alternative to conventional methods of layer-based AM for the manufacture of components designed using topology optimisation. The objectives of the study are to formulate a toolpath-generation algorithm for the extrusion process, to design the testing apparatus and methods for the validation of the proposed extrusion process, and to generate feedback based on the results obtained during testing and validation for possible implementation in topology optimisation software. The outcome of the study is a process by which toolpaths can be generated for simple geometries, and implemented using a mounted extruder serving on to a serial robotmounted build platform. OPSOMMING Die ekstrusie van materiaal langs driedimensionele krommes deur middel van toevoegingsvervaardiging word voorgehou as ʼn alternatief vir konvensionele, topologie-optimeerde, laaggebaseerde toevoegingsvervaardiging. Die doelstellings van hierdie navorsing is om ʼn gereedskapstuk trajek algoritme vir die ekstrusie proses te formuleer, om die toetsapparaat en validasie-metodes vir die voorgestelde proses te ontwerp en om terugvoer te gee aan die hand van die resultate. Die einddoel is om die benadering in te sluit in topologie-optimering sagteware. Die resultaat van hierdie studie is ʼn proses waarvolgens gereedskapstuk trajekte genereer kan word vir eenvoudige geometrieë en geïmplementeer kan word deur die gebruik van ʼn matrys op ʼn serie, robot-gemonteerde bouplatform.

Advances in additive manufacturing technology present new design opportunities for metal parts that would otherwise be infeasible with subtractive manufacturing technologies. Clifford Machines & Technology (Pty) Ltd is an international producer of large mesh welding machines. The research was conducted with the aim of investigating the advantages that can be provided through the redesign of the mesh welding electrodes, for production using additive manufacturing. Simulation studies were applied in order to evaluate the performance of the redesigned electrodes and the results were compared to the existing electrodes. The results show that the electrodes designed for additive manufacturing achieved mass reductions of up to 58.2%. The electrodes were also able to support increases of current density by up to 98%, while operating at a lower temperature than the original electrodes. The study has identified the high initial cost of production and increased power consumption to be the disadvantages of additively manufactured electrodes.

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