Support Diminution Design for Layered Manufacturing of Manifold Surface Based on Variable Orientation Tracking.
Jinghua Xu1,2,3, Mingyu Gao3, Xueqing Feng3
1State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou, China.
3D Printing and Additive Manufacturing
|January 19, 2023
Summary
This study introduces variable orientation tracking (VOT) to minimize support structures in 3D printing, reducing material waste and improving surface precision. The method optimizes substrate normal orientation for enhanced accuracy in layered manufacturing.
Area of Science:
- Additive Manufacturing
- Mechanical Engineering
- Materials Science
Background:
- Layered manufacturing often requires extensive support structures, leading to material waste and surface defects.
- Minimizing external supports is crucial for improving the precision and efficiency of 3D printing processes.
Purpose of the Study:
- To propose a novel support diminution design method based on variable orientation tracking (VOT) for layered manufacturing.
- To theoretically and experimentally minimize external supports, reduce material stripping effect (MSE), and enhance surface precision.
Main Methods:
- Utilizing a cosmic gravity effect criterion to identify surfaces requiring support.
- Calculating optimal substrate normal orientation (SNO) using mathematical harmonic analysis.
- Developing a reconfigurable 6-axis VOT robot with a servo controller for precise orientation and coordinate tracking in 3D printing (3DP).
Main Results:
- Demonstrated significant reduction in material stripping effect (MSE) through experimental validation on a human ear auricle model.
- Quantitatively evaluated and confirmed material savings from diminished external supports.
- Showcased the superiority of VOT over traditional build orientation traversal methods for support reduction.
Conclusions:
- Variable Orientation Tracking (VOT) offers a viable and effective method for minimizing support structures in 3D printing.
- The VOT approach can be widely applied to various layered manufacturing applications requiring precise support curtailment and improved surface quality.
