Hybrid Path Generation Method for Multi-Axis Laser Metal Deposition of Overhanging Thin-Walled Structures

Additive manufacturing has advantages over other traditional manufacturing technologies for the fabrication of complex thin-walled parts. Previous correlation path strategies, when applied to laser metal deposition processes, suffer from contour deposition transboundary and surface "scar" type overstacking. Therefore, this paper proposes a hybrid path generation method for the laser metal deposition process. First, the topological logic of the STL model of the part is restored to reduce redundant calculations at the stage of obtaining the layered contour. Then, the path points are planned on the basis of the offset contours in a helical upward trend to form a globally continuous composite path in space considering the melt channel width. Finally, vectors that adaptively fit to the model surface are generated for the path points as tool orientations and they are optimized by smoothing the rotation angles. The results of experiments conducted on a multi-axis machine equipped with a laser metal deposition module show that the path generated by the proposed method is not only capable of thin-walled structures with overhanging and curved surface features but also improves the surface imperfections of the part due to sudden changes in the angle of rotation while ensuring the boundary dimensions.