Modeling and evaluation of curved layer fused deposition

Fused deposition modeling (FDM), one of the rapid prototyping techniques is a promising technology for rapid manufacture of end use parts direct from CAD files and with the proliferation of cheaper machines, is likely to play a vital role in future polymer processing, challenging traditional processes such as injection moulding in some cases. Research evidence suggests that the road and layer structures would have significant influences on the mesostructure and consequent mechanical behaviour of the resulting polymer part. While adaptive slicing and other deposition schemes have been attempted for different reasons, it is believed that an appropriate deposition scheme is essential to ensure the best inter-road and interlayer connectivity, resulting in a continuous network of polymer chains, as in the case of the traditional processes. The current research proposes the curved layer deposition for FDM, in particular for thin shell-like parts, to ensure fibre continuity. Mathematical models are developed for curved slicing, implemented in a few case studies, parts are printed, and test results suggest marked improvement in the mechanical characteristics of curved layer parts.