Implementation and evaluation of curved layer fused deposition modeling

Abstract

Fused Deposition Modeling (FDM) is an extrusion-based additive manufacturing (AM) process in which a thermoplastic material is extruded through a nozzle. Although it was initially developed for rapid prototyping, advances in the FDM technology have rapidly increased its range of applications. However, the FDM process has inherent disadvantages, such as poor surface finish, severe anisotropic mechanical properties, and increased build time for high-resolution parts. This is the result of the layer-by-layer manufacturing process. To remedy these issues, Curved Layer Fused Deposition Modeling (CLFDM) offers a new building paradigm for FDM in which the material is deposited in curved nonplanar layers. The purpose of this study is to implement a curved-layer toolpath generation algorithm and quantify the benefits of the curved layered methodology over traditional planar layers in printing thin-contoured parts.