Process planning for additive manufacturing of geometries with variable overhang angles using a robotic laser directed energy deposition system

Farzaneh Kaji; Arackal Narayanan Jinoop; Mark Zimny; German Frikel; Kyle Tam; Ehsan Toyserkani

doi:10.1016/j.addlet.2022.100035

Process planning for additive manufacturing of geometries with variable overhang angles using a robotic laser directed energy deposition system

Farzaneh Kaji, Arackal Narayanan Jinoop, Mark Zimny, German Frikel, Kyle Tam, Ehsan Toyserkani

Research output: Contribution to journal › Article › peer-review

Abstract

In the present work, a novel Laser Directed Energy Deposition (LDED) process planning methodology is proposed to build a dome structure with variable overhang angles. Overhang structures with different overhang angles were built where the maximum angle of 35° can be used to build overhang structures without the process and structure compromise. The thin-wall hemispherical dome built using the developed methodology shows the maximum deviation of 2% with respect to the diameter of the original CAD model data. The study paves a way for building high-value, lightweight thin-walled structures with complex cylindrical-based shape (e.g., storage tanks, nozzles, combustion chambers) for engineering applications.

Original language	English
Article number	100035
Journal	Additive Manufacturing Letters
Volume	2
DOIs	https://doi.org/10.1016/j.addlet.2022.100035
Publication status	Published - 31 Jan 2022
Externally published	Yes

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title = "Process planning for additive manufacturing of geometries with variable overhang angles using a robotic laser directed energy deposition system",

abstract = "In the present work, a novel Laser Directed Energy Deposition (LDED) process planning methodology is proposed to build a dome structure with variable overhang angles. Overhang structures with different overhang angles were built where the maximum angle of 35° can be used to build overhang structures without the process and structure compromise. The thin-wall hemispherical dome built using the developed methodology shows the maximum deviation of 2% with respect to the diameter of the original CAD model data. The study paves a way for building high-value, lightweight thin-walled structures with complex cylindrical-based shape (e.g., storage tanks, nozzles, combustion chambers) for engineering applications.",

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AU - Kaji, Farzaneh

AU - Jinoop, Arackal Narayanan

AU - Zimny, Mark

AU - Frikel, German

AU - Tam, Kyle

AU - Toyserkani, Ehsan

PY - 2022/1/31

Y1 - 2022/1/31

N2 - In the present work, a novel Laser Directed Energy Deposition (LDED) process planning methodology is proposed to build a dome structure with variable overhang angles. Overhang structures with different overhang angles were built where the maximum angle of 35° can be used to build overhang structures without the process and structure compromise. The thin-wall hemispherical dome built using the developed methodology shows the maximum deviation of 2% with respect to the diameter of the original CAD model data. The study paves a way for building high-value, lightweight thin-walled structures with complex cylindrical-based shape (e.g., storage tanks, nozzles, combustion chambers) for engineering applications.

AB - In the present work, a novel Laser Directed Energy Deposition (LDED) process planning methodology is proposed to build a dome structure with variable overhang angles. Overhang structures with different overhang angles were built where the maximum angle of 35° can be used to build overhang structures without the process and structure compromise. The thin-wall hemispherical dome built using the developed methodology shows the maximum deviation of 2% with respect to the diameter of the original CAD model data. The study paves a way for building high-value, lightweight thin-walled structures with complex cylindrical-based shape (e.g., storage tanks, nozzles, combustion chambers) for engineering applications.

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JO - Additive Manufacturing Letters

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Process planning for additive manufacturing of geometries with variable overhang angles using a robotic laser directed energy deposition system

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