A Generalized Approach to Non-Layered Fused Filament Fabrication

Abstract

This research attempts to generalize an approach for large-scale, non-layered spatial extrusion. The methodology consists of splitting a volume, representing any arbitrary geometry, into discrete fragments with a finite number of possible arrangements. These fragments are combined in response to a series of design criteria. A novel application of graph theory algorithms is used to generate a continuous and non-overlapping path through the discrete segments. Physical and mechanical issues related to extrusion technology are explored. The computational model takes into consideration the grade and limitations of different kinds of equipment and material properties to counteract fabrication errors with the goal of speeding up the process and eliminating any need for human intervention. This approach is implemented as a cross-platform software product and programming library that can generate robot programs compatible with multiple industrial robot manufacturers. A physical prototype was fabricated using the seminal Panton Chair as a test model. We conclude that the computational approach is sound and most of the issues encountered were due to the equipment used. This will be addressed in future work.