Evaluation of printing feasibility and surface quality in curved layer fused deposition modeling of complex geometries

• A rapid prototyping system to enhance surface finish in parts having non-planar surfaces. • Printing feasibility check in curved layer fused deposition modeling process for complex geometries. • The deployment of nonplanar layers yielded beneficial outcomes for single-curved geometries up to 55° degrees curvature. Fused Deposition Modeling (FDM) is acknowledged for its ability to rapidly produce physical prototypes from virtual prototypes. While being advantageous, the FDM technique has notable limitations in precisely achieving complex curved geometries with an acceptable surface finish. Consequently, an innovative Curved Layer Fused Deposition Modeling (CLFDM) approach utilizing a customized 3D printer has been deployed to produce curved complex geometries with varying surface typologies. The methodology involves slicing the components with planar and non-planar slicing before printing commences. A comparative analysis of non-planar slicing, specifically CLFDM , versus FDM (planar layers) processes for the fabrication of curved geometries is performed. The cut-off inclination for single-ruled geometries, below which the deployment of non-planar layers results in productive outcomes and improved surface finish, is determined. Afterwards, highly complex geometries, such as double-ruled and freeform with varying inclinations, are manufactured by generating a collision-free toolpath. The evaluation of surface finish revealed that the CLFDM process improves surface finish for single-ruled geometries with curvature < 55°. Furthermore, it is clear that using the CLFDM process with a custom 3D printer instead of the conventional FDM process enhances the surface finish by 20 % for single-ruled geometries and by 22.8 % for double-ruled and freeform shapes with low inclination.