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HomeAdvanced Materials ResearchAdvanced Materials Research Vol. 633Feasible Build Orientations for Self-Supporting...

Feasible Build Orientations for Self-Supporting Fused Deposition Manufacture: A Novel Approach to Space-Filling Tesselated Geometries

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Abstract:

Support material is often utilised in additive manufacture to enable geometries that are not otherwise self-supporting. Despite the associated opportunities for innovation, the use of support material also introduces a series of limitations: additional material cost, cost of removal of support material, potential contamination of biocompatible materials, and entrapment of support material within cellular structures. This work presents a strategy for minimising the use of support material by comparing the geometric limits of an additive manufacture process to the build angles that exist within a proposed geometry. This method generates a feasibility map of the feasible build orientations for a proposed geometry with a given process. The method is applied to polyhedra that are suitable for close packing to identify space-filling tessellated structures that can be self-supporting. The integrity of an FDM process is quantified, and using the associated feasibility map, self-supporting polyhedra are manufactured. These polyhedra are integrated with non-trivial geometries to achieve a reduction in consumed material of approximately 50%. Nomenclature

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Advances in Engineering Materials, Product and Systems Design

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Periodical:

Advanced Materials Research (Volume 633)

Pages:

148-168

DOI:

https://doi.org/10.4028/www.scientific.net/AMR.633.148

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Cite this paper

Online since:

January 2013

Authors:

Martin Leary, Mohammad Babaee, Milan Brandt, Aleksandar Subic

Keywords:

Additive Manufacture, Close Packing, Digital Manufacture, Fused Deposition Modeling (FDM), Optimization, Rapid Prototyping (RP), Self-Tessellating Structures

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