Variable-depth curved layer fused deposition modeling of thin-shells

Chen, Lufeng; Chung, Man Fai; Tian, Yunfeng; Joneja, Ajay; Tang, Kai

doi:10.1016/j.rcim.2018.12.016

Cited by 52 publications

(24 citation statements)

References 19 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…However, this model reduced the breaks and staircase with lower printer head motion, while there were some limitations in the control system and kinematic errors. Chen et al (2019a) developed a new curved layer fused deposition modelling (CLFDM) algorithm to print fabricates of various thickness and curvature shape. As seen in Figure 19, a five-axis printer was developed in this research to build variable-thickness models of thin shells.…”

Section: Development In Fused Deposition Modelling Machinementioning

confidence: 99%

An overview of fused deposition modelling (FDM): research, development and process optimisation

Dezaki

Ariffin

Hatami

2021

RPJ

View full text Add to dashboard Cite

Purpose The purpose of this paper is to review research studies on process optimisation and machine development that lead to the enhancement of final products in various aspects of the fused deposition modelling (FDM) process. Design/methodology/approach An overview of the literature, focussing on process parameters, machine developments and material characterisations. This study investigates recent research studies that studied FDM capabilities in printing a vast range of materials from thermoplastics to metal alloys. Findings FDM is one of the most common techniques in additive manufacturing (AM) processes. Many parameters in this technology have effects on three-dimensional printed products. Therefore, it is necessary to obtain the optimum elements, for example, build orientation, layer thickness, nozzle diameter, infill pattern and bed temperature. By selecting a proper variable range of parameters, the layers adhere strongly and building end-use products of high quality are achievable. A vast range of materials and their properties from polymers to composite-based polymers are presented. Novel techniques to print metal alloys and composites are examined to increase the productivity of the FDM process. Additionally, defects such as shrinkage and warpage are discussed to eliminate the system’s limitations and improve the quality of final products. Multi-axis and mobile machines brought enhancements throughout the process to eliminate obstacles such as staircase defects in the conventional FDM process. In brief, recent developments were identified and a summary of major improvements was discussed in this study for future research. Originality/value This paper is an overview that provides information about research and developments in FDM. This review focusses on process optimisation and obstacles in printing polymers, composites, geopolymers and novel materials. Therefore, machine characteristics were examined to find out the accessibility of printing novel materials for different applications.

show abstract

Section: Development In Fused Deposition Modelling Machinementioning

confidence: 99%

An overview of fused deposition modelling (FDM): research, development and process optimisation

Dezaki

Ariffin

Hatami

2021

RPJ

View full text Add to dashboard Cite

show abstract

“…The very first drive plane Q 1 is readily defined-it is simply an extreme plane of S with a normal vector of (−sin(θ * ), cos(θ * ), 0). The approximation as introduced in [6] provides a way to determine the sample density of an NL curve, i.e., the forward step l f between any two adjacent points p i and p i+1 is approximated by the chord length satisfying the chord-error constraint δ * c , which can be explicitly expressed as:…”

Section: Optimized Iso-planar Path Generationmentioning

confidence: 99%

“…Hence, such a pattern is much more suitable for a surface that is geometrically within holes and has a low requirement on filling quality. Chen et al [6] adopted the iso-parametric method to plan a tool path in the parametric domain of the surface, which though does not consider the printing efficiency issue and may generate a skewed and poor-quality tool path if the parametrization or transformation are inappropriate. Recently, Li et al [7] proposed using iso-geodesic distance contours as filling paths where a constant step-over between adjacent paths is ensured.…”

Section: Introductionmentioning

confidence: 99%

Generation of Efficient Iso-Planar Printing Path for Multi-Axis FDM Printing

Xie

Tang

2021

JMMP

Self Cite

View full text Add to dashboard Cite

The emerging multi-axis fused deposition modeling (FDM) printing process is a powerful technology for fabricating complicated 3D models that otherwise would require extensive support structures or suffer the severe stair-case effect if printed on a conventional three-axis FDM printer. However, because of the addition of two rotary axes which enables the printing nozzle to change its orientation continuously, and the fact that the printing layer is now curved, determining how a nozzle printing path to cover the layer becomes a non-trivial issue, since the rotary axes of the printer in general have a much worse kinematic capacity than the linear axes. In this paper, specifically targeting robotic printing, we first propose an efficiency indicator called the material deposition rate which considers both the local geometry of the layer surface and the kinematic capacities of the printer. By maximizing this indicator globally, a best drive plane direction is found, and then the classic iso-planar method is adopted to generate the printing path for the layer, which not only upholds the specified printing quality but also strives to maximize the kinematic capacities of the printer to minimize the total printing time. Preliminary experiments in both computer simulation and physical printing are carried out and the results give a positive confirmation on the proposed method.

show abstract

“…In the literature, Wang et al (2015) generated parallel contours on curved surface by mapping the surface onto a planar plane, but the surface would have distortions after mapping, making the distance between any two neighboring contours unequal. Chen and Tang (2019) reduced the stair-Figure 1 Process planning for a WAAM system step effect by allowing the sliced layers to have variable thicknesses and adjusting the build direction adaptively with respect to the surface normal. Dai et al (2018) and Xu et al (2019) proposed volume printing methods to fabricate parts without support structures.…”

Section: Introductionmentioning

confidence: 99%

Process planning based on cylindrical or conical surfaces for five-axis wire and arc additive manufacturing

Dai

Zhang

2020

RPJ

View full text Add to dashboard Cite

Purpose The study aims to fabricate large metal components with overhangs built on cylindrical or conical surfaces with a high dimensional precision. It proposes methods to address the problems of generating tool-paths on cylindrical or conical surfaces simply and precisely, and planning the welding process on these developable surfaces. Design/methodology/approach The paper presents the algorithm of tool-paths planning on conical surfaces using a parametric slicing equation and a spatial mapping method and deduces the algorithm of five-axis transformation by addressing the rotating question of two sequential points. The welding process is investigated with a regression fitting model on a flat surface, and experimented on a conical surface, which can be flattened onto a flat surface. Findings The paper provides slicing and path-mapping expressions for cylindrical and conical surfaces and a curvature-speed-width (CSW) model for wire and arc additive manufacturing to improve the surface appearances. The path-planning method and CSW model can be applied in the five-axis fabrication of the prototype of an underwater thruster. The CSW model has a confidence coefficient of 98.02% and root mean squared error of 0.2777 mm. The reverse measuring of the finished blades shows the residual deformation: an average positive deformation of about 0.5546 mm on one side of the blades and an average negative deformation of about −0.4718 mm on the other side. Research limitations/implications Because of the chosen research approach, the research results may lack generalizability for the fabrication based on arbitrary surfaces. Originality/value This paper presented an integrated slicing, tool-path planning and welding process planning method for five-axis wire and arc additive manufacturing.

show abstract

Variable-depth curved layer fused deposition modeling of thin-shells

Cited by 52 publications

References 19 publications

An overview of fused deposition modelling (FDM): research, development and process optimisation

An overview of fused deposition modelling (FDM): research, development and process optimisation

Generation of Efficient Iso-Planar Printing Path for Multi-Axis FDM Printing

Process planning based on cylindrical or conical surfaces for five-axis wire and arc additive manufacturing

Contact Info

Product

Resources

About