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Freeform additive manufacturing by vari-directional vari-dimensional material deposition

Che-Chih Tsao (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)
Ho-Hsin Chang (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)
Meng-Hao Liu (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)
Ho-Chia Chen (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)
Yun-Tang Hsu (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)
Pei-Ying Lin (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)
Yih-Lin Chou (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)
Ying-Chieh Chao (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)
Yun-Hui Shen (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)
Cheng-Yi Huang (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)
Kai-Chiang Chan (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)
Yi-Hung Chen (Department of Power Mechanical Engineering, National Tsing Hua University, Hsinchu, Taiwan)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 12 March 2018

Issue publication date: 12 March 2018

389

Abstract

Purpose

The purpose of this paper is to propose and demonstrate a new additive manufacturing approach that breaks the layer-based point scanning limitations to increase fabrication speed, obtain better surface finish, achieve material flexibility and reduce equipment costs.

Design/methodology/approach

The freeform additive manufacturing approach conceptually views a 3D article as an assembly of freeform elements distributed spatially following a flexible 3D assembly structure, which conforms to the surface of the article and physically builds the article by sequentially forming the freeform elements by a vari-directional vari-dimensional capable material deposition mechanism. Vari-directional building along tangential directions of part surface gives surface smoothness. Vari-dimensional deposition maximizes material output to increase build rate wherever allowed and minimizes deposition sizes for resolution whenever needed.

Findings

Process steps based on geometric and data processing considerations were described. Dispensing and forming of basic vari-directional and vari-dimensional freeform elements and basic operations of joining them were developed using thermoplastics. Forming of 3D articles at build rates of 2-5 times the fused deposition modeling (FDM) rate was demonstrated and improvement over ten times was shown to be feasible. FDM compatible operations using 0.7 mm wire depositions from a variable exit-dispensing unit were demonstrated. Preliminary tests of a surface finishing process showed a result of 0.8-1.9 um Ra. Initial results of dispensing wax, tin alloy and steel were also shown.

Originality/value

This is the first time that both vari-directional and vari-dimensional material depositions are combined in a new freeform building method, which has potential impact on the FDM and other additive manufacturing methods.

Keywords

Acknowledgements

The authors thank the Ministry of Science and Technology of the R.O.C. for sponsoring this research (MOST 105-2218-E-007-004), Professor Chen J.S. of the NTHU PME Dept., Professor Chu C.H. of the NTHU IEEM Dept. and Dr Yang V. of the CoreTech System for their various help during the conduction of this research.

Citation

Tsao, C.-C., Chang, H.-H., Liu, M.-H., Chen, H.-C., Hsu, Y.-T., Lin, P.-Y., Chou, Y.-L., Chao, Y.-C., Shen, Y.-H., Huang, C.-Y., Chan, K.-C. and Chen, Y.-H. (2018), "Freeform additive manufacturing by vari-directional vari-dimensional material deposition", Rapid Prototyping Journal, Vol. 24 No. 2, pp. 379-394. https://doi.org/10.1108/RPJ-01-2017-0014

Publisher

:

Emerald Publishing Limited

Copyright © 2018, Emerald Publishing Limited

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