Session: AM3D1.1 - Current and Emerging Trends in AM

Paper Number: 159344

159344 - Kinematic Approach to Curved Surface Fabrication Using Multi-Axis 3D Printing for Improved Mechanical Properties 

In the conventional additive manufacturing process, particularly in Fused Deposition Modeling (FDM), objects and parts are manufactured by layer-by-layer material deposition along the Z-axis direction, and substantial support structures are frequently required to preserve the overhanging features during manufacturing, leading to material waste and increasing postprocessing efforts. This research addresses these shortcomings by introducing an innovative kinematic approach to curved surface fabrication, utilizing a five-axis 3D printing system. The proposed system integrates a 3-axis delta robot with an A-B axis rotating print table, enabling dynamic reorientation of the printing platform. This configuration facilitates support-free printing and enhances the overall quality of printed surfaces. A novel multi-axis slicing algorithm has been designed to optimize toolpaths for curved geometries, minimizing the staircase effect and reducing material usage. This method achieves significantly smoother surface finishes and improves mechanical properties by generating conformal layers aligned with the object's geometry. Experimental evaluations highlight the effectiveness of the five-axis mechanism in enhancing load bearing strength and reducing surface roughness compared to conventional FDM systems. Furthermore, the innovative approach substantially reduces reliance on support structures, reducing material consumption, making it a cost-effective and sustainable solution. This study presents a transformative framework for integrating multi-axis kinematics and advanced slicing algorithms into AM processes. The findings demonstrate the potential of this approach to overcome traditional limitations, providing a pathway for fabricating complex geometries with higher precision, superior mechanical properties, and increased material efficiency. This work lays a solid foundation for developing advanced multi-axis AM systems for applications demanding high-performance components.

Presenting Author: Deepak Kumar Academy of Scientific and Innovative Research

Presenting Author Biography: Deepak Kumar, (Graduate Student Member, ASME) is a Ph.D. Scholar in Biomedical Applications Department at the AcSIR-CSIO Chandigarh. He received a master’s degree in advanced instrumentation from the Academy of
Scientific and Innovative Research (AcSIR), Ghaziabad, Uttar Pradesh, India. His research interests include
industrial robotics, kinematics & dynamics of 3D printing system, modelling & simulations of kinematics structures.