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TECHNICAL PAPERS

Tool Path-Based Deposition Planning in Fused Deposition Processes

[+] Author and Article Information
Wenbiao Han, Mohsen A. Jafari

Department of Industrial & Systems Engineering, Rutgers University, 96 Frelinghuysen Road, Piscataway, NJ 08854

Stephen C. Danforth, Ahmad Safari

Department of Ceramic & Materials Engineering, Rutgers University, 607 Taylor Road, Piscataway, NJ 08854

J. Manuf. Sci. Eng 124(2), 462-472 (Apr 29, 2002) (11 pages) doi:10.1115/1.1455026 History: Received January 01, 2000; Revised March 01, 2001; Online April 29, 2002
Copyright © 2002 by ASME
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References

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Jafari,  M. A., Han,  W., Mohammadi,  F., Safari,  A., Danforth,  S. C., and Langrana,  N. A., 2000, “A Novel System for Fused Deposition of Advanced Multiple Ceramics.” Rapid Prototyping Journal, 6, No. 3, pp. 161–174.
Agarwala, M. K., van Weeren, R., Bandyopadhyay, A., Whalen, P. J., Safari, A., and Danforth, S. C., 1996, “Fused Deposition of Ceramics and Metals: An Overview,” Proceedings of Solid Freeform Fabrication Symposium, Austin, TX, pp. 385–390.
Agarwala,  M. K., Jamalabad,  V. R., Langrana,  N. A., Safari,  A., Whalen,  P. J., and Danforth,  S. C., 1996, “Structural Quality of Parts Processed by Fused Deposition,” Rapid Prototyping Journal, 2, No. 4, pp. 4–19.
Safari,  A., 1999, “Novel Piezoelectric Ceramics and Composites for Sensors and Actuators Applications,” Mater. Res. Innovations, 2, pp. 263–269.
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Figures

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Approaches for improving part quality in the FD processes
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Terminology in vector fill pattern
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Schematic of fused deposition process
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Schematic of steady deposition state
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Speed change at a turn point
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Actual tool path vs. head speed (sample period=10 ms)
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Overfills and underfills due to vector geometry
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Cross section images of road geometry under different offsets
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Modeled deposition road geometry
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Desired deposition with offset f*
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Gap between two adjacent roads
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Bump between two adjacent roads
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Underfills due to change of vector angle (a) even layer of part 13a (b) underfilled layer of part 13b
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Underfill correlation between two adjacent layers (a) current layer of part 14a (b) next layer of part 14b
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Overfill correlation between two adjacent layers (a) current layer of part 15a (b) next layer of part 15b
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Grouping and mapping algorithm
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Grouping result for the vector in Fig. 18
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CAD/CAM procedure with deposition planning in FD process
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Nonlinear relationship between vector segment length and roller speed
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A piezoelectric actuator part designed for testing proposed approach
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Built green parts with removable base using different methods constant roller speed (0.38 counts/ms) (b) constant roller speed (0.48 counts/ms) (c) deposition planning (using varying roller speeds)
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A layer of tool path for second part
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A structural component using two different methods (a) with constant roller speed (0.41 counts/ms) (b) using deposition planning approach

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