DIRECT 3D LAYER METAL DEPOSITION AND TOOLPATH GENERATION

Jianzhong Ruan jzruan@mst.edu Lie Tang Ltx8d@mst.edu Todd E. Sparks tparks@mst.edu Robert G. Landers landersr@mst.edu Frank Loiu liou@mst.edu Department of Aerospace and Mechanical Engineering Missouri University of Science and Technology, Rolla, Missouri 65409, U.S.A. ABSTRACT Multi-axis slicing for solid freeform fabrication (SFF) manufacturing process can yield non-uniform thickness layers, or 3-D layers. Using the traditional parallel layer construction approach to build such a layer leads to a staircase which requires machining or other post processing to form the desired shape. This paper presents a direct 3-D layer deposition approach. This approach uses an empirical model to predict the layer thickness based on experimental data. The toolpath between layers is not parallel; instead, it follows the final shape of the designed geometry and the distance between the toolpath in the adjacent layers varies at different locations. Directly depositing a 3-D layer not only eliminates the staircase effect, but also improves the manufacturing efficiency by shortening the deposition and machining times. A single track deposition experiment has demonstrated these advantages. Thus, it is a beneficial addition to the traditional parallel deposition method