Research on Angle-Adaptive Look-Ahead Compensation Method for Five-Degree-of-Freedom Additive Manufacturing Based on...

To address over-extrusion and forming defects at path corners caused by path overlap in additive manufacturing, this paper proposes an angle-adaptive look-ahead compensation algorithm based on a Sech attenuation curve. This method establishes a mapping model between the path angle and the adaptive look-ahead distance of the overlapping area, aiming to eliminate the material accumulation at the corner by precisely identifying the overlapping area and modulating the flow rate. By building a Beckhoff five-axis 3D-printing device and relying on the TwinCAT control platform, the compensation triggering logic based on PLC real-time Euclidean distance calculation was realized, and a slicing software with dynamic bias compensation was also developed. Experiments were conducted on triangular samples with extreme acute angles of 5°, universal acute angles of 85°, and 90° straight angles for printing verification. The results show that this algorithm can effectively suppress the material over-extrusion and accumulation at the path overlap in multiple angles, achieving a smooth transition of the sharp corners in the printed contour. The research confirms that the algorithm proposed in this study, together with the integrated software and hardware system, can ensure the forming accuracy of extreme and conventional geometric features while also guaranteeing the printing efficiency, providing an important reference for ensuring the quality coordination control of the formation process of extreme geometric features in additive manufacturing.