An Additive Manufacturing Method Using Large-Scale Wood Inspired by Laminated Object Manufacturing and Plywood Technology

Wood-based materials in current additive manufacturing (AM) feedstocks are primarily restricted to the micron scale. Utilizing large-scale wood in existing AM techniques remains a challenge. This paper proposes an AM method-laser-cut veneer lamination (LcVL)-for wood-based product fabrication. Inspired by laminated object manufacturing (LOM) and plywood technology, LcVL bonds wood veneers in a layer-upon-layer manner. As demonstrated by printed samples, LcVL was able to retain the advantageous qualities of AM, specifically, the ability to manufacture products with complex geometries which would otherwise be impossible using subtractive manufacturing techniques. Furthermore, LcVL-product structures designed through adjusting internal voids and wood-texture directionality could serve as material templates or matrices for functional wood-based materials. Numerical analyses established relations between the processing resolution of LcVL and proportional veneer thickness (layer height). LcVL could serve as a basis for the further development of large-scale wood usage in AM.