Tool Path Strategies for Surface Reinforcement in Polymer-Based 3D Printing with an Industrial Robotic Arm
Date of Award
12-12-2024
Degree Name
Ph.D. in Electrical and Computer Engineering
Department
Department of Electrical and Computer Engineering
Advisor/Chair
Raul Ordonez
Abstract
Additive manufacturing (AM) technology is rapidly advancing across diverse fields. For instance, the use of robotic arms in various AM processes has led to significant gains in printing flexibility and manufacturing scalability. However, despite these advancements, there remains a notable research gap concerning the mechanical properties of parts 3D-printed with robotic arms. This study focuses on developing a robotic fused filament fabrication (FFF) 3D-printing process with a layer resolution of 50 μm to 300 μm. The impact of the robotic printing process on the mechanical properties of printed parts is investigated and benchmarked against a commercial FFF 3D printer. In addition, we propose a novel tool path that can vary contour layer thickness within an infill layer to improve mechanical strength by minimizing air gaps between contours. SEM images suggest that this new tool path strategy leads to a significant reduction in the fraction of the void area within the contours, confirmed by a nearly 6% increase in the ultimate tensile strength. Furthermore, a novel strategy for non-planar contours is proposed, specifically designed for thin-shell 3D models. This approach aligns tool paths parallel to the Z-axis, organized into triangular segments, and utilizes planar slicing techniques. The method involves segmenting the point cloud and systematically printing non-planar contours on top of the planar contours. Axial compression testing reveals that samples produced using this strategy exhibit mechanical properties comparable to those of conventional 3D printing. However, distinct fracture patterns are observed: in conventional 3D-printed samples, fractures occur on both inner and outer surfaces, while in non-planar printed samples, fractures are confined to the inner surfaces (planar contours) and do not propagate to the outer non-planar contours. This demonstrates the potential of non-planar printing for improved structural integrity.
Keywords
fused filament fabrication (FFF), robotic 3D printing, mechanical properties, polylactic acid (PLA), layer thickness, non-planar tool path
Rights Statement
Copyright © 2024, author.
Recommended Citation
Veeraboina, Ajith, "Tool Path Strategies for Surface Reinforcement in Polymer-Based 3D Printing with an Industrial Robotic Arm" (2024). Graduate Theses and Dissertations. 7490.
https://ecommons.udayton.edu/graduate_theses/7490
