Advanced
search

To read this content please select one of the options below:

Fused deposition modeling five-axis additive manufacturing: machine design, fundamental printing methods and critical process characteristics

Hongyao Shen (The State Key Laboratory of Fluid Power and Mechatronic Systems, College of Mechanical Engineering, Zhejiang University, Hangzhou, 310027, China and Key Laboratory of 3D Printing Process and Equipment of Zhejiang Province, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China)
Huaidong Diao (The State Key Laboratory of Fluid Power and Mechatronic Systems, College of Mechanical Engineering, Zhejiang University, Hangzhou, 310027, China and Key Laboratory of 3D Printing Process and Equipment of Zhejiang Province, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China)
Shuhua Yue (The State Key Laboratory of Fluid Power and Mechatronic Systems, College of Mechanical Engineering, Zhejiang University, Hangzhou, 310027, China and Key Laboratory of 3D Printing Process and Equipment of Zhejiang Province, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China)
Jianzhong Fu (The State Key Laboratory of Fluid Power and Mechatronic Systems, College of Mechanical Engineering, Zhejiang University, Hangzhou, 310027, China and Key Laboratory of 3D Printing Process and Equipment of Zhejiang Province, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 9 April 2018

887

Abstract

Purpose

The staircase effect and support structure under overhanging geometry are two inherent weaknesses that reduces the surface quality and induces material waste. This paper aims to design a five-axis fused deposition modeling system with interference-free nozzle to solve the problems.

Design/methodology/approach

To facilitate the application of five-axis printing machine, three new printing methods are proposed according to different geometries and application requirements, which include tangential direction printing, normal sculpture printing and compatible printing.

Findings

The static flow beading characteristic is researched to establish the criterion for switching the mode between three-axis printing and five-axis printing. Experiment proves the critical point existing and 51° is the critical point at the given parameters. The concept of dynamic flow beading is proposed. The relationship between equivalent volume and roughness is established based on elaborate experiments, which helps to figure out the boundary between safe area and beading area under different parameters of layer thickness and nozzle diameter.

Originality/value

Three new printing methods are proposed according to different geometries and application requirements, which include tangential direction printing, normal sculpture printing and compatible printing. Considering the special movement situation during five-axis printing process, the dynamic flow beading issue is proposed. The relationship between equivalent volume and roughness is established based on elaborate experiments, which helps to figure out the boundary between safe area and beading area under different parameters of layer thickness and nozzle diameter.

Keywords

Acknowledgements

This work was financially supported by the National Nature Science Foundation of China (No. 51475421), the Science Fund for Creative Research Groups of National Natural Science Foundation of China (No. 51521064), Key research and development plan of Zhejiang Province(No 2018C01073).

Citation

Shen, H., Diao, H., Yue, S. and Fu, J. (2018), "Fused deposition modeling five-axis additive manufacturing: machine design, fundamental printing methods and critical process characteristics", Rapid Prototyping Journal, Vol. 24 No. 3, pp. 548-561. https://doi.org/10.1108/RPJ-05-2017-0096

Publisher

:

Emerald Publishing Limited

Copyright © 2018, Emerald Publishing Limited

Related articles

Manage cookies

We’re listening — tell us what you think

Join us on our journey