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A multi-DOF rotary 3D printer: machine design, performance analysis and process planning of curved layer fused deposition modeling (CLFDM)

Donghua Zhao (State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, China)
Tianqi Li (School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, China)
Beijun Shen (Shanghai Jiao Tong University, Shanghai, China)
Yicheng Jiang (University of Michigan - Shanghai Jiao Tong University Joint Institute, Shanghai, China)
Weizhong Guo (State Key Laboratory of Mechanical System and Vibration, Shanghai Jiao Tong University, Shanghai, China)
Feng Gao (State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, China)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 30 March 2020

Issue publication date: 19 June 2020

717

Abstract

Purpose

The purpose of this paper is to design and develop a rotary three-dimensional (3D) printer for curved layer fused deposition modeling (CLFDM), and discuss some technical challenges in the development.

Design/methodology/approach

Some technical challenges include, but are not limited to, the machine design and control system, motion analysis and simulation, workspace and printing process analysis, curved layer slicing and tool path planning. Moreover, preliminary experiments are carried out to prove the feasibility of the design.

Findings

A rotary 3D printer for CLFDM has been designed and developed. Moreover, this printer can function as a polar 3D printer for flat layer additive manufacturing (AM). Compared with flat layer AM, CLFDM weakens the staircase effect and improves geometrical accuracy and mechanical properties. Hence, CLFDM is more suitable for parts with curved surfaces.

Research limitations/implications

Double extruders have brought improved build speed. However, this paper is restricted to complex process planning and mechanical structures, which may lead to collisions during printing. Meanwhile, the rotation range of the nozzle is limited by mechanical structures, affecting the manufacturing capability of complex curved surfaces.

Originality/value

A novel rotary 3D printer, which has four degrees of freedom and double extruders, has been designed and manufactured. The investigation on the prototype has proved its capability of CLFDM. Besides, this rotary 3D printer has two working modes, which brings the possibility of flat layer AM and CLFDM.

Keywords

Acknowledgements

The authors would like to thank the partial financial support under the project from the National Natural Science Foundation of China (Grant No. 51735009) and Chun-Tsung Program of Shanghai Jiao Tong University.

Citation

Zhao, D., Li, T., Shen, B., Jiang, Y., Guo, W. and Gao, F. (2020), "A multi-DOF rotary 3D printer: machine design, performance analysis and process planning of curved layer fused deposition modeling (CLFDM)", Rapid Prototyping Journal, Vol. 26 No. 6, pp. 1079-1093. https://doi.org/10.1108/RPJ-06-2019-0160

Publisher

:

Emerald Publishing Limited

Copyright © 2020, Emerald Publishing Limited

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