Five-axis additive manufacturing of freeform models through buildup of transition layers

Acclaimed for enabling the fabrication of complex parts, additive manufacturing is confined to established processing and planning methods that contribute impediments to its industrial adoption. The requirement of support structures and poor quality of produced surfaces are some of these impediments. Extension of the manufacturing method to accommodate variable tool orientation can introduce new approaches in process planning that can resolve these obstacles. Therefore, a new 5-axis 3D printer is designed, built and programmed to facilitate implementation of novel 3D curve paths. Common layering methods in additive manufacturing are centered around the idea of intersection of a CAD model with parallel planes or offset surfaces without regards to the form of the part. The use of these inflexible layering patterns leads to staircase effect on the surfaces, inefficient toolpaths and low load-bearing capacity. This article suggests and develops new 5-axis path planning model that takes into account the surface profiles of the freeform part. Path and tool orientation conditions are reexamined to propose planning schemes that prevent staircase effects on shell and solid components. To accomplish this, the material is deposited on successive transition surfaces whose infra-layer thickness varies to allow changes in the form of the surfaces.