Quasi-Uniform Density Non-Solid Infill Strategy for Axisymmetric Non-Planar Additive Manufacturing

• Published in: Applied sciences Vol. 15; no. 11; p. 5899
• Main Authors: Guzman-Bautista, Alvaro, López-Arrabal, Adrián, Sanchez-Oro-Aguado, Elio, Fernández Gorgojo, Andrea, García-Galán, Ramiro, Badesa, Francisco J., Vizan-Idoipe, Antonio
• Format: Journal Article
• Language: English
• Published: Basel MDPI AG 01.06.2025
• Subjects: 3D printing; Additive manufacturing; Algorithms; Cost control; curved layer deposition; Energy consumption; infill strategy; Mechanical properties; Non-Planar Additive Manufacturing; non-solid infills; Ordinary differential equations; path planning; Robots; Spain
• ISSN: 2076-3417; 2076-3417
• DOI: 10.3390/app15115899

Non-solid infill generation in Non-Planar Additive Manufacturing (NPAM) is still an open problem. This is due to mathematical complexities from curvature distortion, as well as bridging limitations inherent in some NPAM processes. Providing solutions to this problem may result in significant energy, build cycle time, and cost savings. In this context, the goal of this paper is to define a workflow for the generation of non-solid infill paths with quasi-uniform density within the layer. This was performed by defining the build geometry through an axisymmetric embedded map methodology, and the infill points were distributed via a geodesic repulsion energy-based algorithm. In addition to these core algorithms, several numeric optimizations were implemented to reduce runtime. The algorithm has been tested on several build platform geometries and slice polygons. The results were satisfactory, achieving a homogeneous kernel density distribution for all cases and reductions in geodesic distance standard deviations of around 70%. A first iteration of a path planning algorithm was also implemented to showcase the intended final results. This methodology is to be combined with other Design for Non-Planar Additive Manufacturing techniques to enable applications in the biomedical field, automotive and aerospace industry, or rapid mold manufacturing.