3D Printing: Conformal Geometry and Multimaterial Additive Manufacturing through Freeform Transformation of Building Layers (Adv. Mater. 11/2021)

Huang, Jigang; Ware, Henry Oliver T.; Hai, Rihan; Shao, Guangbin; Sun, Cheng

doi:10.1002/adma.202170082

Cited by 2 publications

(1 citation statement)

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“…Furthermore, while previous studies have successfully created geometries unattainable with conventional AM through dynamic reorientation of the extrusion nozzle, they move the build plate, which limits the size of existing structures and is unsuitable for fabricating structures onto an existing, fixed surface. [32,35,36] In addition, studies utilizing multiaxis rotation of the extrusion head predominantly used FFF to deposit rapidly solidifying thermoplastics rather than DIW. [37] This is because DIW AM outside of the downward XY plane presents a unique challenge: viscoelastic, shear thinning DIW inks are particularly sensitive to gravitational effects which can cause premature delamination of the structure from the print surface.…”

Section: Introductionmentioning

confidence: 99%

Robotic Conformal Material Extrusion 3D Printing for Appending Structures on Unstructured Surfaces

Armstrong,

Montgomery,

Yue

et al. 2024

Advanced Intelligent Systems

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Fabrication of structures in unstructured conditions is a promising area of bolstering the application spaces of additive manufacturing (AM). One emerging application is appending structures on existing ones that may have nonplanar surfaces in unconventional orientations. However, extrusion‐based AM techniques are limited to printing on structured, planar environments with a fixed single‐nozzle direction. Herein, the authors present a dexterous conformal material extrusion printing method using a six‐axis robotic arm capable of constructing complex parts onto highly unstructured surfaces with rough topographies. The manufacturing method employs a custom algorithm that generates layers consisting of 3D spatial coordinates of print path as well as the extrusion nozzle oriented in the normal direction of the substrate, thereby enabling conformal motion of the extrusion nozzle to the unstructured surface. The capabilities of the surface‐informed robotic conformal 3D printing method to fabricate structures on surfaces with a variety of topographies in unconventional orientations are demonstrated. Finally, via addition of deposited conductive paths, a high‐strength, functional reinforcement capable of in situ deformation monitoring is appended. This work has the potential for reconstructing, repairing, and reinforcing existing structures in human‐limited or inaccessible spaces. Integration of functional elements can also enable in situ sensing, monitoring, and self‐diagnosis.

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Section: Introductionmentioning

confidence: 99%

Robotic Conformal Material Extrusion 3D Printing for Appending Structures on Unstructured Surfaces

Armstrong,

Montgomery,

Yue

et al. 2024

Advanced Intelligent Systems

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Optimization of the Metal Nozzle for High-Temperature Extrusion Additive Manufacturing

Long

et al. 2022

KEM

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Material extrusion additive manufacturing (ME-AM) builds 3D models by extruding materials through a nozzle layer by layer. As the development of materials, an increasing demand of the high-temperature extrusion has emerged in additive manufacturing (AM). While the smooth and stable extrusion process at high temperature relies heavily on the nozzle, the optimization study on the metal nozzle is reported in this work. From current brass and steel nozzles, two optimized nozzles (a steel nozzle with brass embedded and a steel nozzle with brass encircled) have been designed and the thermal conductivity has been studied by simulation analysis. Then the thermal deformation of designed nozzles and traditional nozzles have been investigated at the temperature of 410°C. Conducting the extrusion and printing tests, the extrusion performance of the proposed nozzles has been compared to that of traditional nozzles. The results indicate that the proposed nozzles lead to the better thermal distribution as well as the stronger resistance to thermal deformation compared to the traditional brass nozzle. The designed steel nozzle with brass encircled shows the excellent extrusion performance and printing performance.

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3D Printing: Conformal Geometry and Multimaterial Additive Manufacturing through Freeform Transformation of Building Layers (Adv. Mater. 11/2021)

Cited by 2 publications

References 0 publications

Robotic Conformal Material Extrusion 3D Printing for Appending Structures on Unstructured Surfaces

Robotic Conformal Material Extrusion 3D Printing for Appending Structures on Unstructured Surfaces

Optimization of the Metal Nozzle for High-Temperature Extrusion Additive Manufacturing

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