Abstract
Large Format Additive Manufacturing (LFAM) addresses the limitations of traditional 3D printing, including slow deposition rates, limited scalability, lengthy prints, and high tooling costs for large structures. Current LFAM relies on quasi-planar, 2.5D printing strategies. This fails to reap the advantages of multi-axis printing, such as reduced support material use and the ability to create complex curved surfaces. A pellet-fed, multi-axis, large-format 3D printer was developed, featuring a KUKA robot and linear rail to enable multi-axis capabilities. LFAM’s potential is demonstrated by designing and simulating the printing process for a mold of a composite wing with a winglet.
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