Generation of large scale robotic 3D printing trajectories and optimization of the quality of pieces

Incremental sheet forming is used to form metal sheets on massive dies. However, the waste and time lost due to the machining of dies can be a problem for both companies and the environment. Additive manufacturing is thus a potential alternative to classical machining of dies, but these complex geometries could be challenging for classical layer-by-layer 3D printing techniques. This paper will present an innovative process based on a 3D printing technology using 3-axis systems and a pellet extruder combined with the generation of non-planar trajectories in order to achieve good surface quality. PLA-based parts were realised to evaluate surface quality and mechanical properties. With such a technique, the obtained 3D printed parts were closer to the expected CAD geometries and smoother top surfaces were obtained. These improvements have been made possible through the development of specific post-processors and printing strategies in order to replicate the behaviour of a 3D printer at a larger scale, which is a current challenge in robotic 3D printing.