Open5x: Accessible 5-axis 3D printing and conformal slicing (2202.11426v2)

Abstract: The common layer-by-layer deposition of regular, 3-axis 3D printing simplifies both the fabrication process and the 3D printer's mechanical design. However, the resulting 3D printed objects have some unfavourable characteristics including visible layers, uneven structural strength and support material. To overcome these, researchers have employed robotic arms and multi-axis CNCs to deposit materials in conformal layers. Conformal deposition improves the quality of the 3D printed parts through support-less printing and curved layer deposition. However, such multi-axis 3D printing is inaccessible to many individuals due to high costs and technical complexities. Furthermore, the limited GUI support for conformal slicers creates an additional barrier for users. To open multi-axis 3D printing up to more makers and researchers, we present a cheap and accessible way to upgrade a regular 3D printer to 5 axes. We have also developed a GUI-based conformal slicer, integrated within a popular CAD package. Together, these deliver an accessible workflow for designing, simulating and creating conformally-printed 3D models.

• The paper’s main contribution is demonstrating how to upgrade standard 3-axis FFF printers to 5-axis systems via a novel 2-axis rotating gantry design.
• It details the development of a GUI-driven conformal slicer integrated with Rhino and Grasshopper to optimize toolpaths and feedrate calculations.
• Experimental results showcase improved surface finishes and mechanical properties with non-planar deposition, reducing support needs and overall costs.

An Analysis of Open5x: Enhancing Accessibility in 5-axis 3D Printing

The paper, "Open5x: Accessible 5-axis 3D printing and conformal slicing," presents a novel approach designed to democratize access to multi-axis 3D printing technology by enabling the conversion of prevalent low-cost 3-axis desktop 3D printers to more advanced 5-axis systems. Major contributions include describing the upgrade process from a typical fused filament fabrication (FFF) system to a 5-axis platform and introducing user-friendly software capable of facilitating conformal slicing without extensive computational knowledge prerequisites.

Overview of Technical Contribution

The research highlights the limitations of conventional 3-axis FFF systems, notably the inability to produce smooth surface finishes and homogeneous material properties due to their layer-by-layer deposition process. In response, the authors advocate for a conformal 3D printing methodology, which employs non-planar layer deposition to reduce support material needs, improve mechanical properties, and produce high-quality surface finishes. The substantial advancement claimed is making 5-axis 3D printing more accessible and affordable, historically constrained by significant technical and financial barriers.

Key technical developments outlined include:

1. Hardware Adaptation: The paper provides a comprehensive methodology for upgrading common desktop 3D printers, like the Prusa i3 MK3s, to support five-axis motion. This includes the design of a 2-axis rotating gantry, which is a crucial modification that enables conformal deposition. The project's open-source nature allows extensive customizability and adaptation to other printer models.
2. Software Development: The researchers have developed an accessible GUI-driven conformal slicer that operates within Rhino's CAD environment, employing Grasshopper for toolpath generation. The integration into CAD tools enables visualization and simulation of the printing process in a familiar setting, lowering the skill barrier for potential users. Their slicer optimizes feedrate calculations using inverse kinematics to maintain consistent extrusion, a challenge often faced in 5-axis printing.

Practical and Theoretical Implications

The implications of this advancement are multi-faceted. Practically, this approach can significantly reduce the cost and complexity associated with adopting 5-axis 3D printing, making the technology more attainable for individual makers and smaller enterprises without compromising on quality. Theoretical implications include the potential re-evaluation of design methodologies within additive manufacturing paradigms, allowing for more complex geometries and creating opportunities in diverse domains such as printed electronics and lightweight structures.

Strong Numerical Evidence

The paper exemplifies the practical capability of their system through various printed artifacts, notably achieving support-less overhangs and conformal surface finishes. These results underline the enhanced structural integrity and surface aesthetics achievable with 5-axis conformal printing over standard 3-axis processes, evidenced by microscope imagery and physical objects exhibiting complex geometries.

Speculation on Future Developments

The research underscores a pivotal shift towards more personalizable and versatile 3D printing solutions within the domain of additive manufacturing. Future developments likely include wider accessibility and further usability improvements in multi-axis printing technologies. Moreover, continued development in slicing algorithms and path planning is anticipated, with a focus on environments that require specialized material properties. As this technology becomes more widespread, a surge in the synthesis and customization of printed materials is conceivable, which holds potential for innovations in the fields of healthcare, aerospace, and consumer electronics.

In summary, "Open5x: Accessible 5-axis 3D printing and conformal slicing" elucidates a pathway for extending the utility of current 3D printing technologies. This opens avenues for further research and innovation, fostering broader participation in 5-axis conformal printing applications.