Processes & Toolchain for Automation of Hybrid Direct-Write 3D Printing
Hybrid 3D printing has evolved from a means to rapidly prototype devices to a fully viable means of manufacturing final products. In particular, electronic and electromagnetic devices have been a focus of hybrid 3D printing multi material structures. However, while the hardware capabilities have been around for years, the software capabilities have only begun to catch up. A process and toolchain for hybrid 3D printing is critically needed. This work details a process and toolchain for hybrid 3D printing metal dielectric structures. In it, a basic slicing algorithm is shown along with off-axis printing and conformal printing for arbitrary curvatures. These methods are derived such that devices that are typically printed with a five- or six-axis machine can now be printed with a standard multi-tool three-axis machine. Moreover, these methods are generalized so they can be implemented with any printer, although in this work they are tested with Ultimaker and nScrypt printers. Multiple devices are demonstrated using these new algorithms. Finally, a tool path planning process for hybrid printing functionally-graded materials is shown. The tool path planning needed for printing arbitrary functionally graded materials involves numerous routines including adjusted infill patterns, look-ahead routines, and priming routines. Arbitrary functionally graded devices are demonstrated.
Carranza, Gilbert Thomas, "Processes & Toolchain for Automation of Hybrid Direct-Write 3D Printing" (2022). ETD Collection for University of Texas, El Paso. AAI29999916.