Generating Robot Trajectories for Conformal Three-Dimensional Printing Using Nonplanar Layers

Shembekar, Aniruddha V.; Yoon, Yeo Jung; Kanyuck, Alec; Gupta, Satyandra K.

doi:10.1115/1.4043013

Cited by 50 publications

(23 citation statements)

References 25 publications

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“…Similar studies and conceptual solutions significantly contribute to the increase of interest in the field of non-planar printing. It has an integral place in continuous research in the field of materials, mechanical properties of models, development of structures and software [20].…”

Section: Current State In the Field Of The Use Of Non-planar Layeringmentioning

confidence: 99%

Design of an Atypical Construction of Equipment for Additive Manufacturing with a Conceptual Solution of a Printhead Intended for the Use of Recycled Plastic Materials

et al. 2021

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This article presents the variability of Fused deposition modelling (FDM) technology and the possibilities of its use in the design and implementation of a prototype atypical device. The assumptions of the behaviour of individual components and subsystems of the design result from an extensive application of the finite element method and motion analysis of subsystems and various parts of the structure. The use of this method to such an extent accelerated the design process and its implementation. The proposal itself reflects the current state of this technology and its focus is on improving sustainable development. As is generally known, great efforts are currently being made to reduce plastic waste volume and its environmental burden. The proposed concept is modified to replace the final treatment of the top layers of the models, called “ironing” by non-planar layering of material. At the same time, it points out the advantages of this method in reducing energy requirements and the time required to produce models. The conclusion is a conceptual design of a printhead for a proposed prototype, designed to use recycled FDM, intending to streamline the possibility of recycling with little serial and piece production. This process thus closes the circle of opportunities published by us, which in the future can contribute to the optimisation of this technology towards increasing the efficiency of resource use, reduction of energy demands and environmental burden.

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Section: Current State In the Field Of The Use Of Non-planar Layeringmentioning

confidence: 99%

Design of an Atypical Construction of Equipment for Additive Manufacturing with a Conceptual Solution of a Printhead Intended for the Use of Recycled Plastic Materials

et al. 2021

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“…Conformal printing has emerged as a process to deposit silver inks on curvilinear surfaces to create conductive paths [42]; however, some recent studies were published about path planning for conformal 3D printing using FFF. Shembekar et al [43] proposed an algorithm for conformal printing using non-planar layers and evaluated the differences in roughness between a surface finish when printed using planar layer slicing and the proposed algorithm. The algorithm aims at collision-free trajectory planning using a projection method: (1) a grid is created on the XY plane (0.5 mm spacing); (2) vertices of each triangle are projected to the XY plane;…”

Section: Non-planar Path Planning For 3d Printingmentioning

confidence: 99%

“…Most of the work published, to the best of our knowledge, about conformal-curved trajectory printing is focused on the improvement of the surface finish (reducing the stairstepping effect) with improvement in the mechanical performance as a consequence, and a reduction in the number of layers needed for the part to be printed. Due to this, the mostused paths for curved printing are limited to zigzag or circular patterns [43,44,46]. In these works, printing paths consisted of equidistantly offsetting starting curves, which restrict the points to define the printing trajectory.…”

Section: Non-planar Path Planning For 3d Printingmentioning

confidence: 99%

Algorithm for the Conformal 3D Printing on Non-Planar Tessellated Surfaces: Applicability in Patterns and Lattices

et al. 2021

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In contrast to the traditional 3D printing process, where material is deposited layer-by-layer on horizontal flat surfaces, conformal 3D printing enables users to create structures on non-planar surfaces for different and innovative applications. Translating a 2D pattern to any arbitrary non-planar surface, such as a tessellated one, is challenging because the available software for printing is limited to planar slicing. The present research outlines an easy-to-use mathematical algorithm to project a printing trajectory as a sequence of points through a vector-defined direction on any triangle-tessellated non-planar surface. The algorithm processes the ordered points of the 2D version of the printing trajectory, the tessellated STL files of the target surface, and the projection direction. It then generates the new trajectory lying on the target surface with the G-code instructions for the printer. As a proof of concept, several examples are presented, including a Hilbert curve and lattices printed on curved surfaces, using a conventional fused filament fabrication machine. The algorithm’s effectiveness is further demonstrated by translating a printing trajectory to an analytical surface. The surface is tessellated and fed to the algorithm as an input to compare the results, demonstrating that the error depends on the resolution of the tessellated surface rather than on the algorithm itself.

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“…Dai et al [25] recently developed a support-free volume printing system equipped with a 6-DOF robotic arm. Shembekar et al [26] present a method for conducting conformal 3D printing of freeform surfaces by collision-free trajectories, and this method has been validated on a 6-DOF robotic arm. These approaches deposit materials along 3D tool paths and require relatively expensive devices and control systems to move all DOFs together during the fabrication process.…”

Section: Multi-axis 3d Printingmentioning

confidence: 99%

General Support-Effective Decomposition for Multi-Directional 3-D Printing

Dai

Fang

et al. 2020

IEEE Trans. Automat. Sci. Eng.

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We present a method for fabricating general models with multi-directional 3D printing systems by printing different model regions along with different directions. The core of our method is a support-effective volume decomposition algorithm that minimizes the area of the regions with large overhangs. A beam-guided searching algorithm with manufacturing constraints determines the optimal volume decomposition, which is represented by a sequence of clipping planes. While current approaches require manually assembling separate components into a final model, our algorithm allows for directly printing the final model in a single pass. It can also be applied to models with loops and handles. A supplementary algorithm generates special supporting structures for models where supporting structures for large overhangs cannot be eliminated. We verify the effectiveness of our method using two hardware systems: a Cartesian-motion based system and an angular-motion based system. A variety of 3D models have been successfully fabricated on these systems.Note to Practitioner Abstract-In conventional planar-layer based 3D printing systems, supporting structures need to be added at the bottom of large overhanging regions to prevent material collapse. Supporting structures used in single-material 3D printing technologies have three major problems: being difficult to remove, introducing surface damage, and wasting material. This research introduces a method to improve 3D printing by adding rotation during the manufacturing process. To keep the hardware system relatively inexpensive, the hardware, called a multi-directional 3D printing system, only needs to provide unsynchronized rotations. In this system, models are subdivided into different regions, and then the regions are printed in different directions. We develop a general volume decomposition algorithm for effectively reducing the area that needs supporting structures. When supporting structures cannot be eliminated, we provide a supplementary algorithm for generating supports compatible with multi-directional 3D printing. Our method can speed up the process of 3D printing by saving time in producing and removing supports.

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Generating Robot Trajectories for Conformal Three-Dimensional Printing Using Nonplanar Layers

Cited by 50 publications

References 25 publications

Design of an Atypical Construction of Equipment for Additive Manufacturing with a Conceptual Solution of a Printhead Intended for the Use of Recycled Plastic Materials

Design of an Atypical Construction of Equipment for Additive Manufacturing with a Conceptual Solution of a Printhead Intended for the Use of Recycled Plastic Materials

Algorithm for the Conformal 3D Printing on Non-Planar Tessellated Surfaces: Applicability in Patterns and Lattices

General Support-Effective Decomposition for Multi-Directional 3-D Printing

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