Dimension synthesis of a 2T2R curved layer FDM 3D printer

3D printing or Additive Manufacturing (AM) is significant in various applications. The authors' previous research indicates that higher-degree-of-freedom (DOF) 3D printers have the potential for curved layer printing and multi-direction AM. Hence, this paper focuses on designing a novel 2T2R FDM 3D printer. Performance-chart-based design methodology (PCbDM) has been used for multiple parameters optimization problems due to its reliability, globality, and intuition. While its limitation is the number of optimization parameters less than four. The printer's print head is attached to a planar parallel 1T1R mechanism (4R1P, 3R1P, and passive P). Objectives and requirements require the print head to move over a more considerable distance with a constant swing range and proper pressure angle. So, the 4R1P five-bar (virtual double-rocker, crank-rocker, and rocker-crank) has been investigated to facilitate PCbDM. Meanwhile, one DOF remote center of motion (RCM) mechanism has been integrated for decoupling motion control. Finally, the selected parameters are verified by comparing the numerical and simulation results and experiments. Besides, this novel 3D printer's initial feasibility of flat and curved layer printing is studied with several printed parts to give qualitative analyses. This early-stage work generally intends to investigate the dimension synthesis and show the resulting 2T2R-type rotary 3D printer's initial feasibility for curved printing. The research can help people understand how to carry out the dimension synthesis of 4R1P and a novel mechanism with multi-chain with the help of Grashof criteria to reduce the design space dimensionality.