Autonomous direct freeform fabrication strategy for multi-axis additive manufacturing

Xiao, Xinyi; Lee, Yousub; Feldhausen, Thomas

doi:10.1007/s00170-025-15329-w

Autonomous direct freeform fabrication strategy for multi-axis additive manufacturing

Journal Article · Fri Mar 14 00:00:00 EDT 2025 · International Journal of Advanced Manufacturing Technology

DOI:https://doi.org/10.1007/s00170-025-15329-w· OSTI ID:2538221

Xiao, Xinyi ^[1]; Lee, Yousub ^[2]; Feldhausen, Thomas ^[3]

University of North Texas, Denton, TX (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); University of Texas at El Paso, TX (United States)

Multi-axis additive manufacturing (M-AM) enables precise material deposition along both planar and curved layers, eliminating the need for support structures through a continuous material deposition approach. In contrast to conventional 2-dimensional planar layers constrained to a fixed building orientation, the deposition on freeform layers demands the specification of guided curves to determine material deposition directions which are no longer to be fixed to a build direction. There are challenges that arise when fabricating components with multiple “build” directions, necessitating the decomposition of geometries and the specification of guided curves for the resulting volumes. Furthermore, multi-axis systems introduce heightened challenges due to an increased degree of freedom in motion. Consequently, the potential risks of collision between the deposited geometry and the motion platform become a notable concern. This research proposes a freeform layering algorithm to address the challenge of seamless transitions between planar and curved layers in the process planning of M-AM. The algorithm computes 3D “printable” layers by leveraging topological information derived from the geometry to be built and integrates collision-free manufacturability considerations into the computational process. These accumulated volumes serve as a “substrate” and support volumes for subsequent deposition, allowing later layers to be built without the need for additional support material. In conclusion, the proposed method successfully devises a freeform layering approach suitable for intricate models that demand substantial support, thus enabling the fabrication of diverse geometries in a manner previously unachievable.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2538221

Journal Information:: International Journal of Advanced Manufacturing Technology, Journal Name: International Journal of Advanced Manufacturing Technology Vol. 137; ISSN 0268-3768

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
3D “printable” layers
Collision-free
Freeform
Multi-axis AM

Autonomous direct freeform fabrication strategy for multi-axis additive manufacturing

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