Research on a Support-Free Five-Degree-of-Freedom Additive Manufacturing Method

When using traditional 3D printing equipment to manufacture overhang models, it is often necessary to generate support structures to assist in the printing of parts. The post-processing operation of removing the support structures after printing is time-consuming and wastes material. In order to solve the above problems, a support-free five-degree-of-freedom additive manufacturing (SFAM) method is proposed. Through the homogeneous coordinate transformation matrix, the forward and inverse kinematics equations of the five-degree-of-freedom additive manufacturing device (FAMD) are established, and the joint variables of each axis are solved to realize the five-axis linkage of the additive manufacturing (AM) device. In this research work, initially, the layered curve is obtained through the structural lines of the overhang model, and a continuous path planning of the infill area is performed on it, and further, the part printing experiments are conducted on the FAMD. Compared with the traditional three-axis additive manufacturing (TTAM) method, the SFAM method shortens the printing time by 23.58% and saves printing materials by 33.06%. The experimental results show that the SFAM method realizes the support-free printing of overhang models, which not only improves the accuracy of the parts but also the manufacturing efficiency of the parts.