Fused deposition modeling five-axis additive manufacturing: machine design, fundamental printing methods and critical process characteristics

Purpose - The staircase effect and support structure under overhanging geometry are two inherent weaknesses that reduces the surface quality and induces material waste. This paper aims to design a five-axis fused deposition modeling system with interference-free nozzle to solve the problems. Design/methodology/approach - To facilitate the application of five-axis printing machine, three new printing methods are proposed according to different geometries and application requirements, which include tangential direction printing, normal sculpture printing and compatible printing. Findings - The static flow beading characteristic is researched to establish the criterion for switching the mode between three-axis printing and five-axis printing. Experiment proves the critical point existing and 51 degrees is the critical point at the given parameters. The concept of dynamic flow beading is proposed. The relationship between equivalent volume and roughness is established based on elaborate experiments, which helps to figure out the boundary between safe area and beading area under different parameters of layer thickness and nozzle diameter. Originality/value - Three new printing methods are proposed according to different geometries and application requirements, which include tangential direction printing, normal sculpture printing and compatible printing. Considering the special movement situation during five-axis printing process, the dynamic flow beading issue is proposed. The relationship between equivalent volume and roughness is established based on elaborate experiments, which helps to figure out the boundary between safe area and beading area under different parameters of layer thickness and nozzle diameter.