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A method of additive manufacturing (AM) for the extrusion of material along three-dimensional curves is proposed as an alternative to conventional methods of layer-based AM for the manufacture of components designed using topology optimisation. The objectives of the study are to formulate a toolpath-generation algorithm for the extrusion process, to design the testing apparatus and methods for the validation of the proposed extrusion process, and to generate feedback based on the results obtained during testing and validation for possible implementation in topology optimisation software. The outcome of the study is a process by which toolpaths can be generated for simple geometries, and implemented using a mounted extruder serving on to a serial robot-mounted build platform.

DEVELOPMENT OF A METHOD OF ADDITIVE MANUFACTURING BY MATERIAL EXTRUSION ALONG THREE-DIMENSIONAL CURVES