Additive manufacturing of non-planar layers with variable layer height

Pelzer, Lukas; Hopmann, Christian

doi:10.1016/j.addma.2020.101697

Cited by 22 publications

(13 citation statements)

References 14 publications

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“…But some limitations are there in non-planar printing such as collision and nozzle orientation. These limitations can be removed by redesigning the extruder nozzle geometry, even adding an axis to gain motion flexibility [3], [41]. When viewing from this aspect, the planar slicing stays behind non-planar slicing in terms of surface quality and mechanical property.…”

Section: Discussionmentioning

confidence: 99%

“…The second one is whole non-planar slicing in which a non-planar toolpath is generated from the first sliced layer to the last layer (top surface). This is also called active Z printing or variable depth curved layer; layers are not planar (See Figure 4) [1], [3]. In this slicing method, the extruder is in motion in z-direction according to the top layer geometry.…”

Section: Non-planar Slicingmentioning

confidence: 99%

“…However, produced parts by AM are not efficient completely; besides mechanical properties, geometrically aesthetic appearance has importance. In the traditional AM process, the model is sliced layer by layer as planar in order to create a tool path, and the model is manufactured with 2.5D axes [3]- [5]. Considering if there is a curvature surface that will be manufactured additively, some stair-step effects are observed that significantly affects surface quality.…”

Section: Introductionmentioning

confidence: 99%

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Non-Planar Toolpath for Large Scale Additive Manufacturing

Eyerci̇oğlu

Aladağ

2021

International Journal of 3D Printing Technologies and Digital Industry

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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. One of these methods is non-planar slicing. The stair-stepping effect was significantly decreased by this method. The attempts have been made generally for the FDMprinted objects, however, there is no or fewer efforts have been made for parts of large-scale additive manufacturing (LSAM). Due to higher deposition rates 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. Moreover, a preliminary experimental study of 3D printing with a non-planar toolpath was carried out and the results were presented.

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Section: Discussionmentioning

confidence: 99%

Section: Non-planar Slicingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Non-Planar Toolpath for Large Scale Additive Manufacturing

Eyerci̇oğlu

Aladağ

2021

International Journal of 3D Printing Technologies and Digital Industry

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“…Constant-depth CLFD has made a very significant contribution to increasing stiffness and strength [2]. Further, variable-depth CLFD [3,4], has improved surface finishing by reducing/eliminating the stair-stepping effect. To improve structural and mechanical properties while reducing material use, Tao and Leu [5] and McCaw and Cuan-Urquizo [6] proposed manufacturing non-planar lattices or cellular structures to serve as potential mechanical metamaterials.…”

Section: Introductionmentioning

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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“…This is especially visible where the colour changes from grey to yellow, and could be applied to alter mechanical properties of the finished print. Image reproduced from (Pelzer and Hopmann, 2021). .…”

Section: Figurementioning

confidence: 99%

Assessing Non-Planar Slicing and Carbon Fibre Filament Additives as Steps Towards 3D-Printed Drone Propellers

Palmer¹

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Propeller design dramatically influences the performance of a drone and its ability to complete a mission. Operators in the field cannot carry the best propeller for any possible conditions, but with the advent of capable end-user 3D printers, may be able to manufacture them. This research assesses how non-planar model slicing and short-chopped carbon-fibre additives affect the mechanical performance of printed parts and viability of printed propellers. Creep testing simulating propeller thrust loading found coupons varied greatly in time to failure, although benefits of carbon-fibre additives were detected. Drop tests assessed impact behaviour, finding no link between material or slicing style and performance for a realistic propeller geometry. Simpler geometry resulted in both factors affecting performance, indicating possible benefits when applied in suitable situations. Results can be used to make informed selections of material and slicing type, also guiding future attempts at 3D-printing propellers.Firstly, I would like to thank my thesis supervisor Dr. Jeremy Laliberté, who oversaw my work from conception to completion. Thank you for continuously spending time helping me direct my work, find resources, understand problems, and turn my ideas into plans that could be executed.From my time spent in the lab, thank you to Chris Bassindale, who was always around to help with the practical aspects of my research and troubleshoot when things were going wrong. Thanks also to Stephan Biljan, who took the time to teach me about 3D scanning and helped me achieve much better results than I could have alone.Without the help of the MAE machine shop, I would not have been able to obtain many of the parts required to make my research happen. Thank you to Alex Proctor and the rest of the machine shop team for your guidance on materials, designs, and the build process, your patience in helping me carry out what work I could do myself, and your expertise in machining the parts I could not.Much of the assistance I received ended up coming from my fellow students. Thank you to Mila Kanvesky for being willing to answer all of the many 3D-printing questions I had and giving me a head-start on understanding the elements underpinning my thesis, as well as to Hayat El Fazani and Rahul Shah for teaching me about the processes used in their own work and how I might apply them.iii Finally, having spent my first year at Carleton doing everything remotely, I would like to thank those who supported me at home: my partner, Emily Semple, and my mother, Patricia Palmer. Without their motivation and encouragement, I'm not sure I would have been able to begin this thesis at all, let alone finish it.

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Additive manufacturing of non-planar layers with variable layer height

Cited by 22 publications

References 14 publications

Non-Planar Toolpath for Large Scale Additive Manufacturing

Non-Planar Toolpath for Large Scale Additive Manufacturing

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

Assessing Non-Planar Slicing and Carbon Fibre Filament Additives as Steps Towards 3D-Printed Drone Propellers

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