Enhancing Non-Planar 3d Printing of Thermosetting Prepolymers: Predictive Design and Modification

Abstract

Additive Manufacturing (AM) is evolving rapidly, becoming a highly versatile fabrication technology. While AM excels in manufacturing intricate models, existing methods can be proven inadequate for the fabrication of curved structures. Conventional AM processes rely solely on generating extrusion paths on a horizontal plane, leading to potential inaccuracies and disconnections in the final parts. This study addresses this limitation by introducing a novel AM method for printing on non-planar structures. An algorithm is established to develop the program structure for non-planar printing. A visual programming language is employed to develop a program that can generate print paths for curved structures. A unique extrusion mechanism system is designed and printed to facilitate the printing process. The developed system is put to the test by printing free-form structures using thermoset pre-polymers. The impacts of several print parameters on print quality are analyzed. A case-dependent dynamic extrusion multiplier is implemented to have better control while printing the thermosetting pre-polymeric materials. The results demonstrate the efficacy of non-planar 3D printing in overcoming the previous limitations associated with conventional planar fabrication processes. Notably, this method facilitates the manufacturing of complex structures while preserving the printed components\u27 functional integrity