A 5D DoF Parallel Kinematic Controler For Big Area Additive Manufacturing

The presented research includes controller and control strategies for 5D profiling in material extrusion based big-area assistive manufacturing. Current state of the art in additive manufacturing (AM) is primarily dominated by a 2.5D layered approach, that induce staircase effects on angled surfaces. This effect introduces manufacturing restrictions in terms of accuracy capabilities. Capabilities that may lead to the requirement of expensive extra process steps in the AM process to obtain the required surface finish of final part components [1]. In addition, the 2.5D layered approach further restricts the full 3D deposition movement required in many high strength continuous fiber composite components. Restrictions that prevent AM from venturing into high strength large scaled applications, with build envelopes above 1m.
In this initial study, investigations are made in the possibility of creating a five degrees of freedom (5DoF) controller system, for a material extrusion based machine. The investigation aims to show how this implementation might help the AM field to move from its traditional 2.5D AM (conventional layered approach) into true 3-dimensional AM.