Testbed for Multilayer Conformal Additive Manufacturing

Abstract

Over the last two decades, additive manufacturing (AM) or 3D printing technologies have become pervasive in both the public and private sectors. Despite this growth, there has been little to no deviation from the fundamental approach of building parts using planar layers. This undue reliance on a flat build surface limits part geometry and performance. To address these limitations, a new method of applying material onto or around existing surfaces with multilayer, thick features will be explored. Prior work proposes algorithms for defining conformal layers between existing and desired surfaces, however this work does not address the derivation of deposition paths, trajectories, or required hardware to achieve this new type of deposition. This paper presents (1) the derivation of deposition paths given a prescribed set of layers; (2) the design, characterization, and control of a proof-of-concept testbed; and (3) the derivation and application of time evolving trajectories subject to the material deposition constraints and mechanical constraints of the testbed. Derivations are presented in a general context with examples extending beyond the proposed testbed. Results show the feasibility of conformal material deposition (i.e., onto and around existing surfaces) with multilayer, thick features.