ADVANCED METHODS FOR A NOVEL FUSED FILAMENT FABRICATION PROCESS ACCOMMODATING VARIABLE BEAD WIDTH

Date

2023-4-28

Author

Gharehpapagh, Bahar

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Material Extrusion Additive Manufacturing (MEAM) has revolutionized the production of complex designs while minimizing the amount of effort required due to its simple production pipeline. However, MEAM naturally comes with a well-known trade-off; higher build resolution often tends to enhance the product quality at the cost of a slower build rate. Nozzles, the standard tool for extrusion in MEAM, have evolved into a crucial component of the process for controlling the build resolution of the products. The purpose of this study is to offer a novel extrusion system that makes use of a rotating nozzle with an unconventional aperture, in contrast to its typical (i.e., circular-orifice) counterparts. The unique nozzle configuration that lacks axial symmetry allows for precise control over the effective dimension of the extrusion via rotational guiding. By positioning the oblong orifice at intermediate orientations, the presented approach seeks to provide continuously variable intralayer and interlayer resolutions for MEAM processes. This work explores the distinctive characteristics of this new nozzle design as well as the potential uses of the novel extrusion system. Improving accuracy with a rectangular-orifice nozzle necessitates the development of new process planning methodologies. The study also focuses on new path planning and trace adjustment strategies to cover the following issues: (i) production of precision outer and inner shells; (ii) fast infill-pattern generation. Despite the fact that the above-mentioned strategies make good use of extrusion- and feed-rate modulation to a certain extent, the performance improvement is evaluated comparatively via a number of versatile test cases.

Subject Keywords

Material Extrusion, Adaptive Resolution, Rectangular-Orifice Nozzle, Variable Bead Width

URI

https://hdl.handle.net/11511/103200

Collections

Graduate School of Natural and Applied Sciences, Thesis