Ultimately, however, most researchers have realized the limitations presented by the deposition of planar layers. Structural analyses have been performed to assess the best printing direction, while others have studied the proper orientation using FEA safety factors. In previous studies, anisotropy of mechanical properties has been used for strengthening models, with infill and microstructures being adapted also for better topology. (d) Compared to the planar layer-based 3D printing with optimized printing direction, the objects fabricated by our method can withstand up to 203% loads in the physical tensile tests.
Toolpaths are optimized to supervise the fabrication of curved layers on a dual-material multi-axis 3D printer (c) using fused deposition of filaments. Compatible curved layers of supporting structures are also constructed for fabricating models with large overhangs. Given a 3D model under certain loading (a), our method decomposes the model into curved layers (b) that optimizes the anisotropic strength of the 3D printed object while incorporating the manufacturing constraints. Samples for the study were created on an FDM 3D printer. Using finite element analysis (FEA), fields were optimized for collision-free printing, and toolpaths generated on the curved layers to align filaments in the desired directions. This research uses the new framework to take advantage of the anisotropy, creating “field-based optimization” for fabricating curved layers (and better control) for supporting structures. This is in contrast to more conventional methods typically used for strengthening parts such as modifying geometry, optimizing parameters like printing orientation or infill percentage and structure, or performing post-treatment processing via thermal or chemical features. In the case of this research, however, anisotropy is actually used to improve the strength of 3D printed objects by over two times. Due to the relative weakness of inter-layer bonding, the Z-axis is much weaker than the X and Y axes. International researchers have created a novel framework for strengthening 3D prints by aligning filaments, detailing their study in the recently published “ Reinforced FDM: Multi-Axis Filament Alignment with Controlled Anisotropic Strength.”Īs has long been shown, anistropy is typically a weakness of 3D printing, particularly in fused deposition modeling processes.
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