Direct 3d Layer Metal Deposition and Toolpath Generation


Multi-axis slicing for solid freeform fabrication (SFF) manufacturing process can yield non-uniform thickness layers, or 3-D layers. Using the traditional parallel layer construction approach to build such a layer leads to a staircase which requires machining or other post processing to form the desired shape. This paper presents a direct 3-D layer deposition approach. This approach uses an empirical model to predict the layer thickness based on experimental data. The toolpath between layers is not parallel; instead, it follows the final shape of the designed geometry and the distance between the toolpath in the adjacent layers varies at different locations. Directly depositing a 3-D layer not only eliminates the staircase effect, but also improves the manufacturing efficiency by shortening the deposition and machining times. A single track deposition experiment has demonstrated these advantages. Thus, it is a beneficial addition to the traditional parallel deposition method.

Meeting Name

ASME 2008 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference


Mechanical and Aerospace Engineering

Keywords and Phrases

Metals; Manufacturing; Machining; Shapes; Thickness; Construction; Geometry

Document Type

Article - Journal

Document Version


File Type





© 2008 American Society of Mechanical Engineers (ASME), All rights reserved.

Publication Date

01 Jan 2008