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

Area of Science:

• Additive Manufacturing
• Geometric Feature Formation
• Process Control

Background:

• Path overlap in additive manufacturing causes over-extrusion and defects at corners.
• Existing methods struggle with precise material modulation at sharp angles.
• Accumulated material at path corners degrades printed part quality.

Purpose of the Study:

• To develop an angle-adaptive look-ahead compensation algorithm for additive manufacturing.
• To eliminate material accumulation and forming defects at path corners.
• To improve the forming accuracy and efficiency of printing extreme geometric features.

Main Methods:

• An angle-adaptive look-ahead compensation algorithm based on a Sech attenuation curve was proposed.
• A mapping model between path angle and adaptive look-ahead distance was established.
• A Beckhoff five-axis 3D-printing device and TwinCAT control platform were utilized, with PLC real-time Euclidean distance calculation and dynamic bias compensation slicing software.

Main Results:

• The algorithm effectively suppressed over-extrusion and material accumulation at path overlaps for angles including 5°, 85°, and 90°.
• Smooth transitions were achieved at sharp corners in printed contours.
• Experimental verification demonstrated the algorithm's capability in handling various geometric features.

Conclusions:

• The proposed algorithm, integrated with the hardware and software system, ensures forming accuracy for extreme and conventional geometric features.
• The method guarantees printing efficiency while improving quality coordination control.
• This research provides a valuable reference for optimizing additive manufacturing processes for complex geometries.