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In multi-axis fused deposition modeling (FDM) printing systems, support-free curved layer fabrication is realized by continuous transition of the printer nozzle orientation. However, the ability to print 3D models with complex geometric (e.g., high overhang) and topological (e.g., high genus) features is often restricted by various manufacturability constraints inherent to a curved layer design process. The crux in a multi-axis printing process planning pipeline is to design feasible curved layers and their tool paths that will satisfy both the support-free condition and other manufacturability constraints (e.g., collision-free). In this paper, we propose a volumetric curved layer decomposition method that strives to not only minimize (if not prevent) collision-inducing local shape features of layers, but also enable adaptive layer thickness to comply with a new volumetric error-based surface quality criterion. Our method computes an optimal Radial Basis Functions (RBF) field to modify the fabrication sequence field, from which, the iso-surface layers are extracted to design the corresponding multi-axis printing tool paths. A method to fine-tune variable nozzle orientations on each resulting curved layer is then proposed to overcome possible collisions in high-genus geometries. To validate the concept and exhibit its potential, several support-free fabrication experiments and comparisons with the conventional geodesic field-based slicing are presented, and the results give a preliminary confirmation of the feasibility and advantages of the proposed method. [ABSTRACT FROM AUTHOR]

Continuous 3+2-axis additive manufacturing (AM) is an emerging AM technology that overcomes the signature problems of the need of support structures and the staircase effect of the traditional 3-axis AM. This paper presents a novel process planning framework for automatically generating a multi-axis support-free printing path for continuous 3+2-axis AM of an arbitrary freeform part. The framework is based on the geometric processing of skeletonization and decomposition and is particularly suitable for a part with distinct multiple trunk-branch structures. The physical printing experimental results carried out by the authors indicate that the proposed framework has performed well and fabricated some challenging models with large overhangs and twisty spatial topologies. [ABSTRACT FROM AUTHOR]

The original published article contained a mistake. [ABSTRACT FROM AUTHOR]