Abstract
Fused Deposition Modelling (FDM) is a manufacturing process to build components in a layer-by-layer approach through extrusion of polymers from a movable nozzle, allowing for significantly higher degrees of complexity over machined parts. Current FDM systems typically use actuation provided through a gantry or delta structural layout, operating through depositing successive planar layers in a 2.5D process; it has been shown in numerous studies the bonding between layers has significantly lower strength than the homogeneous material or in-plane properties - an issue which can be mitigated through the deposition of curved layers. This paper compares four differing structural layouts of FDM systems (gantry, delta, Stewart Platform, and arm-based) to identify the key advantages of an arm-based method as the increased workspace and manipulability enabling “Additive Finalisation” of components, and suitability for curved layer FDM. Details are then presented of the open-source implementation and evaluation of a 6 degree-of-freedom arm-based FDM printer at the University of Bristol.
Highlights
Additive Manufacture (AM) was defined in ISO/ASTM 52900 as a “process of joining materials to make parts from 3D model data, usually layer upon layer” [1]
Song et al implemented a parallel kinematic robot, with the extruder affixed to a 6 degree of freedom (DOF) Stewart Platform [7]; a platform comprising of 6 linear actuators affixed to the extruder
MIT implanted an early instance of robotic arm-based AM, through use of a Kuka arm with changeable end effectors allowing for foam extrusion, a milling tool to machine the foam to a fine finish, and the Fused Deposition Modelling (FDM) of polymers [10]
Summary
Additive Manufacture (AM) was defined in ISO/ASTM 52900 as a “process of joining materials to make parts from 3D model data, usually layer upon layer” [1]. Components produced through AM are constructed through fusion of raw materials, as opposed to subtractive manufacture where they are machined from a larger block. Multi-Directional Layered Deposition (MDLD) was explored by Singh et al [6], where overhangs, which typically require support structures, were eliminated through changing the angle of the slicing plane relative to the build surface. This process allows for the division of a CAD model into supported and unsupported sections and, through varying the slicing orientation between sections, eliminated the requirement for printing of supports for overhanging sections. Future developments are presented, along with details on access to the open source code developed during this project
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