Development of a Low-Cost Parallel Kinematic Machine for Multi-Directional Additive Manufacturing

Most additive manufacturing (AM) processes are layer-based with three linear motions in the X, Y and Z axes. However, there are drawbacks associated with such limited motions, e.g. non-conformal material properties, stair-stepping effect, and limitations on building-around-inserts. Such drawbacks will limit additive manufacturing to be used in more general applications. To enable 6-axis motions between a tool and a work piece, we investigate a Stewart mechanism and developed a low-cost prototype system for multi-directional additive manufacturing processes such as the Fused Deposition Modeling (FDM) and CNC Accumulation. The technical challenges in developing such an AM system are discussed including the hardware design, motion planning and modeling, platform constraint checking, tool motion simulation, and platform calibration. Several test cases are performed to illustrate the capability of the developed multi-directional additive manufacturing system.