Chinese Journal of Lasers, Volume. 49, Issue 14, 1402302(2022)

Latest Research Progress and Prospect of Process Planning Algorithms of Multiaxis Support-Free 3D Printing for Complex Structure

Jiangzhao Zhang, Huiliang Tang, Chu Wang, Xiaoxuan Wu, and Yu Long*
Author Affiliations
  • Institute of Laser Intelligent Manufacturing and Precision Processing, School of Mechanical Engineering, Guangxi University, Nanning 530004, Guangxi, China
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    Figures & Tables(28)
    A general workflow of 3D printing preprocessing
    Number of publications on multiaxis 3D printing[20]
    Non-uniform slicing method[30]
    Unit layer slicing method[31]. (a) Unit layer;(b) result of slicing; (c) unit layer after deposition
    Offset slicing method[32]. (a) Base surface of contour; (b) offset slices obtained from base surface
    An illustration of method proposed by Lee and Jee[33]. (a) STL model; (b) overhang/overcutting identification;(c) overhang/overcutting volume decomposition; (d)(e) slicing in multiple directions
    Illustration of decomposition-regrouping method[34]. (a) Sub-volumes, feature regions (red), and base region;(b) grouped sub-volumes; (c) slicing in multiple directions
    Cylindrical coordinate slicing method[35]. (a) Revolving part; (b) cylindrical coordinate; (c) intersection contour of slice with overhang structure; (d) mapped overhanging structure at Cartesian coordinate
    Nonplanar slicing method proposed by Zhao et al[36]. (a) Decomposed volumes; (b) offset surfaces; (c) trimmed surfaces; (d) five-axis toolpaths
    Non-uniform slicing method based on centroidal axis[37]. (a) Solid model; (b) centroidal axis; (c) centroidal axis and solid model; (d) decomposed result; (e) slicing result
    Illustration of method proposed by Wang et al[40]. (a) Input Y shape model; (b) three extracted skeletal polylines of S1γ, S2γ, and S3γ; (c) coarse segmentation result based on skeletons from Fig. 11(b) by evaluating shape diameter; (d) find the risky facets of model surface under a variable printing direction; (e) partition the model into two printable parts A* and B* with a partition plane; (f) skeleton S4γ, as part of S3γ, is reserved B* after plane clipping, and a single skeleton S5γ is re-extracted from trunk model A*; (g) C, E, and G printed in fixed directions; (h) final decomposition result
    Model decomposition method proposed by Wu et al[41]. (a) Input 3D model; (b) extracted skeleton; (c) distribution of shape diameter metric; (d) initial decomposition and print order results; (e) result after merging (B+A); (f) final result after fine decomposition (meet manufacturability requirements)
    Volume decomposition algorithm proposed by Dai et al[48]. (a) Input 3D model; (b) voxel discretization and accumulative voxel sequence; (c) generating curved layers based on Fig. 13(b); (d) a detailed view on a computed toolpath
    Volume decomposition algorithm proposed by Xu et al[51]. (a) Original mesh model; (b) generated iso-geodesic contours; (c) reconstructed surface layers with no intersection
    Volume decomposition algorithm proposed by Fang et al[55]. (a) A bunny-head model H is represented by a tetrahedral mesh T; (b) principal stresses with values are visualized by colors; (c) a vector-field V(x) is optimized according to the principle of reinforcement and the fabrication constraints; (d) a scalar-field G(x) is obtained by enforcing ∇G(x) to follow V(x); (e) preliminary curved layers are generated by extracting the iso-surfaces from G(x); (f) an orientation of fabrication is determined by considering the accessibility of printer head and regions with large overhangs are detected by a sampling based method; (g) a vector-field V(x) is extrapolating V(x) for supporting structure; (h) final curved layers are extracted from the governing fields for 3D printing; (i) toolpaths are generated for curved layers according to the principal stresses
    Illustrate of ellipsoid based curved slicing[57]. (a) A characteristic ellipsoid of a sub-entity; (b) intermediate ellipsoid generation
    Schematic of the method proposed by Kapil et al[59]. (a) Position of cladding torch and substrate; (b) tilted substrate for 5-axis outer contour deposition; (c) vertical substrate for 2.5 axis area filling
    Horizontal planes with equal distances h between each other generate different layer thicknesses in the welding direction[61]
    A novel deposition strategy for creating overhangs proposed by Dai et al[62-63]. (a) A common strategy of depositing filling paths layer by layer; (b) a novel strategy of depositing the overhanging segment as a support; (c) deposition of filling paths
    Illustrate of staircase effect under three conditions[23]. (a) P⊆Q; (b) Q⊆P; (c) P⊄Q
    Comparison of methods between planar slicing and slightly curved slicing[68]. (a) Planner slicing method; (b) slightly curved slicing method
    Helical slicing method[69]. (a) Model input; (b) generate slicing planes; (c) obtain planar slices; (d) generate direction vectors; (e) generate helical points; (e) generate helical toolpath
    Slicing and path generation method and actual print results for RotBot[81]
    Singularity aware motion planning[93]. (a) Singularity aware optimization is not used; (b) singularity aware optimization is used
    • Table 1. Comparison of decomposition results based on constrained optimization methods[46]

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      Table 1. Comparison of decomposition results based on constrained optimization methods[46]

      Original input modelDecomposed result by Wu et al[41]Decomposed result by Xu et al[45]Decomposed result by Xiao et al[46]
      Cannot be processed
      Cannot be processed
    • Table 2. Comparison of characteristics of constraint-based optimization methods

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      Table 2. Comparison of characteristics of constraint-based optimization methods

      Ref.YearCategorySuitable type of modelsDecomposing with planes or surfacesLimitationPlatform typeDOF
      Dep.headBuild plate
      [41]2017Shape-analysis-based decomposition, constrained fine tuningMulti-branched structure; volumes with non-shape edgesPlanesRoot node of print sequence needs to be manually intervention6-DOF robotic arm03 trans., 3 orient.
      [42]2019Constrained optimization, heuristic search(ant colony algorithm)Volumes with non-shape edges; ring-like models(compared with results of Ref. [41])PlanesNumber of cutting planes need to be manually intervention; not efficient5-axis CNC machine3 trans.2 orient.
      [44]2019Constrained optimization, gravity-effect partitionOverhanging features with sharp concave edges or concave loopsPlanesSeveral type of workpieces like hollow cubic cannot be partitioned5-axis CNC machine3 trans.2 orient.
      [45]2019Constrained optimization, downward flooding searchTree structurePlanesSub-volumes which may interference with printing nozzle should be merged manually3 -axis(tested their method by assembly parts),--
      [43]2020Constrained optimization, beam-guided searchVolumes with non-shape edges (compared with results of Ref. [45])PlanesRotational axis should be chosen carefully6-DOF robotic arm03 trans., 3 orient.
      [46]2020Constrained optimizationOverhanging features with sharp concave edges or concave loops; ring-like models; volumes with non-shape edgesPlanes/surfacesRotational axis should be chosen carefully3 -axis (tested their method by assembly parts)--
    • Table 3. Summary and comparison of methods based on curved layer decomposition

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      Table 3. Summary and comparison of methods based on curved layer decomposition

      Ref.YearCategorySuitable type of modelsLimitationPlatform typeDOF
      Generation method of initial curved layersGeneration method of curved toolpathClassification of curved toolpathOptimization method of orientation-smoothingDep. headBuild plate
      [47]2018Growing field generated by determining an order of voxel accumulationGenerated by FWP-MMP methodContinuous fermal spiral tool-pathLow pass filtering sampling; quaternion interpolationVolumes with non-shape edgesDiscretization error; Not efficient; Lower surfaces quality6-DOF robotic arm03 trans., 3 orient.
      [51]2019Scalar field computed based on MMP algorithmGeodesic distance field computed based on MMP methodContour-parallel path5-point sampling with Gaussian hemisphere interpolationVolumes with non-shape edgesPotential local interference; low productivity6-DOF robotic arm03 trans., 3 orient.
      [53]2020Geodesic distance field based on heat methodGeodesic distance field based on heat methodContour-parallel path-Multi-branched structureParts with complicated topologies may lead to collision5-axis printing system3 trans.3 trans., 3 orient.
      [55]2020Scalar-field according to stress analysis(based on Abaqus)Scalar-field according to stress analysis(based on Abaqus)Hybrid strategy(contour-parallel path and directional- parallel path)-Volumes with non-shape edgesSupports needed; low productivity5-axis CNC machine3 trans.2 orient.
      [56]2021Temperature field based on COMSOLBased on heat methodContour-parallel path-Overhanging features are sharp concave edges or concave loopsPotential local interference; not efficient5-axis printing system3 trans.2 orient.
      [57]2022Ellipsoidal slicingField based methodContour-parallel path(iso-cusp height printing path)-Volumes with non-shape edgesComplex algorithms; global interference is not considered5-axis printing system3 trans.3 trans., 3 orient.
      [58]2021----Thin-walled structureAffected by human experience6-DOF robotic arm03 trans., 3 orient.
    • Table 4. Summary of process planning methods of multi-axis support-free 3D printing

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      Table 4. Summary of process planning methods of multi-axis support-free 3D printing

      MethodCategorySuitable type of modelsCharacteristicImpact of manufacturing processMain application
      Overhang structure decompositionPlanner multi-axisOverhanging features are sharp concave edges or concave loopsEasy to control; efficientAlleviated anisotropy; high surface qualityFDM, WAAM, LDMD
      SkeletonizationPlanner multi-axis; nonuniformMulti-branched or tree structureEasy algorithms; robustAlleviated anisotropy; high surface qualityFDM, WAAM, LDMD
      Constraint optimizationPlanner multi-axis; uniformVolumes with non-shape edgesAnisotropy; easy to control toward 3+2-axis; not efficientAlleviated anisotropy; weak stiffnessFDM
      Curved layer decompositionNonplanar; nonuniformVolumes with non-shape edgesComplex algorithms; not efficientIsotropy; lower surfaces qualityFDM
      Inner/outer volume decompositionPlanner multi-axis; uniformVolumes with non-shape edgesEasy algorithms; efficient; easy to controlIsotropy; lower surfaces quality; few defects or voids in inner volumeWAAM, LDMD
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    Jiangzhao Zhang, Huiliang Tang, Chu Wang, Xiaoxuan Wu, Yu Long. Latest Research Progress and Prospect of Process Planning Algorithms of Multiaxis Support-Free 3D Printing for Complex Structure[J]. Chinese Journal of Lasers, 2022, 49(14): 1402302

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    Paper Information

    Category: Multifunctional Structure Manufacturing

    Received: Dec. 22, 2021

    Accepted: Feb. 10, 2022

    Published Online: Jul. 6, 2022

    The Author Email: Long Yu (longyu@gxu.edu.cn)

    DOI:10.3788/CJL202249.1402302

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