Generation of large scale robotic 3D printing trajectories and optimization of the quality of pieces

by

Generation of large scale robotic 3D printing trajectories and optimization of the quality of pieces

François Rosoux, Henri Appeldoorn, Didier Garray, Eric Beeckman

Sirris, the collective centre of the Belgian technological industry, Seraing 4102, Belgium.

DOI:

https://doi.org/10.7494/cmms.2023.1.0794

Abstract:

Incremental sheet forming is used to form metal sheets on massive dies. However, the waste and time lost due to the machining of dies can be a problem for both companies and the environment. Additive manufacturing is thus a potential alternative to classical machining of dies, but these complex geometries could be challenging for classical layer-by-layer 3D printing techniques. This paper will present an innovative process based on a 3D printing technology using 3-axis systems and a pellet extruder combined with the generation of non-planar trajectories in order to achieve good surface quality. PLA-based parts were realised to evaluate surface quality and mechanical properties. With such a technique, the obtained 3D printed parts were closer to the expected CAD geometries and smoother top surfaces were obtained. These improvements have been made possible through the development of specific post-processors and printing strategies in order to replicate the behaviour of a 3D printer at a larger scale, which is a current challenge in robotic 3D printing.

Cite as:

Rosoux, F., Appeldoorn, H., Garray, D., & Beeckman, R. (2023). Generation of large scale robotic 3D printing trajectories and optimization of the quality of pieces. Computer Methods in Materials Science, 23(1), 35–41. https://doi.org/10.7494/cmms.2023.1.0794

Article (PDF):

Keywords:

3D printing, Non-planar, Robotics, Polymers, Pellet extrusion

Publication dates:

Received: 13.10.2022, Accepted: 12.07.2023, Published: 28.08.2023

References:

Ahlers, D., Wasserfall, F., Hendrich, N., & Zhang, J. (2019). 3D printing of nonplanar layers for smooth surface generation. 2019 IEEE 15th International Conference on Automation Science and Engineering. https://www.doi.org/10.1109/COASE.2019.8843116.

Carolo, L. (2021). Annealing PLA for stronger 3D prints: 2 easy ways. All3DP. Retrieved May 11, 2023, from: https://all3dp.com/2/annealing-pla-prints-for-strength-easy-ways/#:~:text=In%20terms%20of%20material%20strength,other%203D%20printed%20annealed%20materials.

Dave, H.K., & Davim, J.P. (Eds.) (2021). Fused Deposition Modeling Based 3D Printing. Springer Cham.

Etienne, J., Ray, N., Panozzo, D., Hornus, S., Wang, C.C.L., Martínez, J., McMains, S., Alexa, M., Wyvill, B., & Lefebvre, S. (2019). CurviSLicer: Slightly curved slicing for 3-axis printers. ACM Transactions on Graphics, 38(4), 1–10.

Mitropoulou, I., Bernhard, M., & Dillenburger, B. (2020). Print Paths Key-framing Design for non-planar layered robotic FDM printing. In: SCF ‘20: Proceedings of the 5th Annual ACM Symposium on Computational Fabrication (6, pp. 1–10). https://doi.org/10.1145/3424630.3425408.

Mueller, R.K. (2022, March 26). 3D printing: Slicing with non-planar geometries. XYZdims. Retrieved June 29, 2023, from: https://xyzdims.com/2022/03/26/3d-printing-slicing-with-non-planar-geometries/.

NatureWorks (n.d.). Ingeo Biopolymer 3D870 Technical Data Sheet. Retrieved April 28, 2023, from: https://www.natureworksllc.com/~/media/Files/NatureWorks/Technical-Documents/Technical-Data-Sheets/TechnicalDataSheet_3D870_monofilament_pdf.pdf.

Nugroho, A., Ardiansyah, R., Rusita, L., & Larasati, I.L. (2018). Effect of layer thickness on flexural properties of PLA (PolyLactid Acid) by 3D printing. Journal of Physics: Conference Series, 1130, 012017. https://doi.org/10.1088/1742-6596/1130/1/012017.

O’Connell, J. (2021, January 31). Non-Planar 3D Printing: All You Need to Know. All3DP. Retrieved July 10, 2023, from: https://all3dp.com/2/non-planar-3d-printing-simply-explained/.

Prakash, C., Singh, S., & Ramakrishna, S. (2022). Additive, Subtractive, and Hybrid Technologies. Springer Cham.

Shembekar. A., Yoon, Y.J., Kanyuck, A., & Gupta S.K. (2019). Generating robot trajectories for conformal 3D printing using non-planar layers. Journal of Computing and Information Science in Engineering, 19(3), 031011. https://doi.org/10.1115/1.4043013.

Singh, R., & Davim, J.P. (Eds.) (2019). Additive Manufacturing. Applications and Innovations. CRC Press, Taylor et Francis Group.

Wohlers Associates (2022). Wohlers Report 2022. 3D printing and additive manufacturing. Global state of the industry.