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Full text release has been delayed at the author's request until December 14, 2026

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Tool Path Strategies for Surface Reinforcement in Polymer-Based 3D Printing With an Industrial Robotic Arm

VEERABOINA, AJITH K
http://orcid.org/0009-0005-0484-5195
http://rave.ohiolink.edu/etdc/view?acc_num=dayton1734015501737366

Abstract Details

2024, Doctor of Philosophy (Ph.D.), University of Dayton, Electrical and Computer Engineering.
Additive manufacturing (AM) technology is rapidly advancing across diverse fields. For instance, the use of robotic arms in various AM processes has led to significant gains in printing flexibility and manufacturing scalability. However, despite these advancements, there remains a notable research gap concerning the mechanical properties of parts 3D-printed with robotic arms. This study focuses on developing a robotic fused filament fabrication (FFF) 3D-printing process with a layer resolution of 50 μm to 300 μm. The impact of the robotic printing process on the mechanical properties of printed parts is investigated and benchmarked against a commercial FFF 3D printer. In addition, we propose a novel tool path that can vary contour layer thickness within an infill layer to improve mechanical strength by minimizing air gaps between contours. SEM images suggest that this new tool path strategy leads to a significant reduction in the fraction of the void area within the contours, confirmed by a nearly 6% increase in the ultimate tensile strength. Furthermore, a novel strategy for non-planar contours is proposed, specifically designed for thin-shell 3D models. This approach aligns tool paths parallel to the Z-axis, organized into triangular segments, and utilizes planar slicing techniques. The method involves segmenting the point cloud and systematically printing non-planar contours on top of the planar contours. Axial compression testing reveals that samples produced using this strategy exhibit mechanical properties comparable to those of conventional 3D printing. However, distinct fracture patterns are observed: in conventional 3D-printed samples, fractures occur on both inner and outer surfaces, while in non-planar printed samples, fractures are confined to the inner surfaces (planar contours) and do not propagate to the outer non-planar contours. This demonstrates the potential of non-planar printing for improved structural integrity.
Raul Ordonez, Dr. (Advisor)
Electrical Engineering; Mechanical Engineering; Plastics; Robotics
fused filament fabrication (FFF), robotic 3D printing, mechanical properties, polylactic acid (PLA), layer thickness, non-planar tool path

Recommended Citations

Citations

  • VEERABOINA, A. K. (2024). Tool Path Strategies for Surface Reinforcement in Polymer-Based 3D Printing With an Industrial Robotic Arm [Doctoral dissertation, University of Dayton]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=dayton1734015501737366

    APA Style (7th edition)

  • VEERABOINA, AJITH. Tool Path Strategies for Surface Reinforcement in Polymer-Based 3D Printing With an Industrial Robotic Arm. 2024. University of Dayton, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=dayton1734015501737366.

    MLA Style (8th edition)

  • VEERABOINA, AJITH. "Tool Path Strategies for Surface Reinforcement in Polymer-Based 3D Printing With an Industrial Robotic Arm." Doctoral dissertation, University of Dayton, 2024. http://rave.ohiolink.edu/etdc/view?acc_num=dayton1734015501737366

    Chicago Manual of Style (17th edition)

dayton1734015501737366
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This open access ETD is published by University of Dayton and OhioLINK.
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