A robotic 3D printing system for supporting-free manufacturing of complex model based on FDM technology

Purpose 3D printing technology has the characteristics of fast forming and low cost and can manufacture parts with complex structures. At present, it has been widely used in various manufacturing fields. However, traditional 3-axis printing has limitations of the support structure and step effect due to its low degree of freedom. The purpose of this paper is to propose a robotic 3D printing system that can realize support-free printing of parts with complex structures. Design/methodology/approach A robotic 3D printing system consisting of a 6-degrees of freedom robotic manipulator with a material extrusion system is proposed for multi-axis additive manufacturing applications. And the authors propose an approximation method for the extrusion value E based on the accumulated arc length of the already printed points, which is used to realize the synchronous movement between multiple systems. Compared with the traditional 3-axis printing system, the proposed robotic 3D printing system can provide greater flexibility when printing complex structures and even realize curved layer printing. Findings Two printing experiments show that compared with traditional 3D printing, a multi-axis 3D printing system saves 47% and 79% of materials, respectively, and the mechanical properties of curved layer printing using a multi-axis 3D printing system are also better than that of 3-axis printing. Originality/value This paper shows a simple and effective method to realize the synchronous movement between multiple systems so as to develop a robotic 3D printing system that can realize support-free printing and verifies the feasibility of the system through experiments.