Assessing layer deviations and correction for robotic polymer 3D printing applications.

Additive manufacturing (AM), often referred to as 3D printing, is a manufacturing technique that involves the creation of complex objects layer-by-layer while providing design flexibility. The broad spectrum of additive manufacturing applications in aerospace, medicine, automotive industries, etc., using high-value materials necessitates a precise final product with minimal wastage. However, the print's dependence on optimizing parameters such as nozzle diameter, printing speed, extrusion speed, nozzle temperature and other multifaceted factors can contribute to deviations from the intended design. This paper introduces a closed-loop in-situ assessment of layer height deviations using point cloud data to ensure real-time printed part modification. The printing is done using a direct-fed pellet screw extruder mounted on top of 6 degrees of freedom robotic arm. A structured light 3D scanner is used to obtain point cloud data. A Robot Operating System (ROS) based digital toolchain is employed to have seamless communication between all nodes of the AM system. The layer-by-layer printing is observed using an in-house CAM solution, which examines the point cloud data and compares it to the original CAD model. The deviations are analyzed, and the path of the next layer is re-planned to adjust for the digression in the previous layer. This control loop ensures that the final product meets the desired quality standards at minimum cost and efficient time and increases the opportunity for rapid prototyping and iterative design improvements. [ABSTRACT FROM AUTHOR]