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Differentiable modelling and optimization of multi-planar slicing for multi-axis additive manufacturing.

Vibhas Mishra1, Jun Wu1

  • 1Sustainable Design Engineering, Faculty of Industrial Design Engineering, Delft University of Technology, Landbergstraat 15, 2628CE Delft, Zuid-Holland The Netherlands.

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Summary

Multi-planar deposition in wire arc additive manufacturing significantly reduces distortion by using distinct printing directions for each sub-part. This novel approach offers an order-of-magnitude improvement over traditional methods for complex geometries.

Keywords:
Fabrication sequence optimizationMulti-axis additive manufacturingMulti-planar slicingThermally induced distortionWire arc additive manufacturing

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Area of Science:

  • Manufacturing Engineering
  • Materials Science & Engineering

Background:

  • Wire arc additive manufacturing (WAAM) faces challenges with residual stresses and distortions.
  • Multi-axis additive manufacturing offers potential solutions through advanced deposition strategies.

Purpose of the Study:

  • To develop a novel continuous and differentiable formulation for multi-planar slicing in WAAM.
  • To reduce distortion in WAAM by optimizing deposition strategies.

Main Methods:

  • A pseudo-time field parameterizes the part segmentation into sub-parts.
  • An orientation field defines distinct printing directions for each sub-part.
  • Gradient-based optimization is enabled by the differentiable formulation.

Main Results:

  • The multi-planar deposition strategy was applied to reduce distortion in WAAM.
  • Numerical examples with complex geometries (holes, overhangs, underhangs) were tested.
  • Distortion was reduced by an order of magnitude compared to conventional planar strategies.

Conclusions:

  • The proposed differentiable multi-planar slicing formulation effectively reduces distortion in WAAM.
  • This method is suitable for complex geometries and offers significant improvements over planar strategies.