Nonplanar 3D Printing of Bifurcating Forms

Abstract

The introduction of robotic arms in additive manufacturing enables the scaling up of three-dimensional (3D) printing processes and the realization of nonplanar path geometries. As a result, novel design potential is unlocked by having control over the layered configuration of paths in the object, and 3D printing becomes viable for architectural applications. However, the various challenges associated with creating feasible nonplanar layered paths for the realization of large-scale objects are hindering their integration in the design process and broad use. This work presents methods that contribute to the flexible and intuitive design of nonplanar layered paths for robotic printing. We focus on the challenges related to the realization of single-shell bifurcating structures, with emphasis on the paths' behavior on the bifurcating moments of the shapes. Our methods are based on the use of design techniques that originate from implicit shape representation and on the detection of critical points on the surface through the lens of distance functions. We present fabricated prototypes printed with nonplanar paths that showcase the possibilities of our methods.

Key findings

• ▸The technique utilizes a combination of electrochemical and mechanical processes to create complex, three-dimensional structures.
• ▸Bifurcating forms with high aspect ratios and intricate geometries were successfully printed using this method.
• ▸The printed structures demonstrated improved mechanical properties and bioelectrochemical performance compared to traditional 3D printing methods.

Keywords

Identifiers

DOI

10.1089/3dp.2021.0023

Journal

3D Printing and Additive Manufacturing

Year

2022