Slicing algorithms for multi-axis 3-D metal printing of overhangs

Abstract

A group of 3D metal printing or Additive metal manufacturing (AMM) processes, officially categorized as 'directed energy deposition (DED)' according to American Society for Testing and Materials (ASTM) classification, has enabled the building of full dense metallic tools and parts using metal powders precisely delivered and controlled with no powder bed. Mold making and metalworking are being taken in an entirely new direction. The overhang/undercut problem in DED processes, as much as other Additive manufacturing (AM) processes, has long remained unsolved, and the ones equipped with more than 3-axis tool mechanism turn out to be capable of depositing overhang/undercut features onto the part to be made. Multi-axis machines introduced for resolving the problem, however, require advanced preprocess software support for the process management that controls multi-axis tool paths. This study proposes slicing algorithms, sophisticatedly designed for the control of the tool paths on a 5-axis base table, to build overhang/undercut features. A methodical approach, using an auto-partitioning algorithm for generating three-dimensional layer (3DL) information, is proposed in this study, and various overhang features, as case studies, have been investigated and implemented by using the proposed method.