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Volume 15
Issue 11
10.3390/app15115899
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Quasi-Uniform Density Non-Solid Infill Strategy for Axisymmetric Non-Planar Additive Manufacturing

by
Alvaro Guzman-Bautista
1,*,
Adrián López-Arrabal
1,
Elio Sanchez-Oro-Aguado
1,
Andrea Fernández Gorgojo
1,
Ramiro García-Galán
2,
Francisco J. Badesa
3 and
Antonio Vizan-Idoipe
1
1
Mechanical Engineering Department, ETSI Industriales, Universidad Politécnica de Madrid, 2, José Gutiérrez Abascal St., 28006 Madrid, Spain
2
Management Engineering Department, ETSI Industriales, Universidad Politécnica de Madrid, 2, José Gutiérrez Abascal St., 28006 Madrid, Spain
3
Center for Automation and Robotics (CAR) UPM-CSIC, Universidad Politécnica de Madrid, 2, José Gutiérrez Abascal St., 28006 Madrid, Spain
*
Author to whom correspondence should be addressed.
Appl. Sci. 2025, 15(11), 5899; https://doi.org/10.3390/app15115899
Submission received: 21 April 2025 / Revised: 16 May 2025 / Accepted: 22 May 2025 / Published: 23 May 2025
(This article belongs to the Section Additive Manufacturing Technologies)
Versions Notes

Featured Application

The methodology presented in this work is to be applied in Robot-based Non-Planar Additive Manufacturing processes, with a particular interest in material extrusion and directed energy deposition processes.

Abstract

Non-solid infill generation in Non-Planar Additive Manufacturing (NPAM) is still an open problem. This is due to mathematical complexities from curvature distortion, as well as bridging limitations inherent in some NPAM processes. Providing solutions to this problem may result in significant energy, build cycle time, and cost savings. In this context, the goal of this paper is to define a workflow for the generation of non-solid infill paths with quasi-uniform density within the layer. This was performed by defining the build geometry through an axisymmetric embedded map methodology, and the infill points were distributed via a geodesic repulsion energy-based algorithm. In addition to these core algorithms, several numeric optimizations were implemented to reduce runtime. The algorithm has been tested on several build platform geometries and slice polygons. The results were satisfactory, achieving a homogeneous kernel density distribution for all cases and reductions in geodesic distance standard deviations of around 70%. A first iteration of a path planning algorithm was also implemented to showcase the intended final results. This methodology is to be combined with other Design for Non-Planar Additive Manufacturing techniques to enable applications in the biomedical field, automotive and aerospace industry, or rapid mold manufacturing.
Keywords: Non-Planar Additive Manufacturing; non-solid infills; infill strategy; path planning; curved layer deposition Non-Planar Additive Manufacturing; non-solid infills; infill strategy; path planning; curved layer deposition

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MDPI and ACS Style

Guzman-Bautista, A.; López-Arrabal, A.; Sanchez-Oro-Aguado, E.; Fernández Gorgojo, A.; García-Galán, R.; Badesa, F.J.; Vizan-Idoipe, A. Quasi-Uniform Density Non-Solid Infill Strategy for Axisymmetric Non-Planar Additive Manufacturing. Appl. Sci. 2025, 15, 5899. https://doi.org/10.3390/app15115899

AMA Style

Guzman-Bautista A, López-Arrabal A, Sanchez-Oro-Aguado E, Fernández Gorgojo A, García-Galán R, Badesa FJ, Vizan-Idoipe A. Quasi-Uniform Density Non-Solid Infill Strategy for Axisymmetric Non-Planar Additive Manufacturing. Applied Sciences. 2025; 15(11):5899. https://doi.org/10.3390/app15115899

Chicago/Turabian Style

Guzman-Bautista, Alvaro, Adrián López-Arrabal, Elio Sanchez-Oro-Aguado, Andrea Fernández Gorgojo, Ramiro García-Galán, Francisco J. Badesa, and Antonio Vizan-Idoipe. 2025. "Quasi-Uniform Density Non-Solid Infill Strategy for Axisymmetric Non-Planar Additive Manufacturing" Applied Sciences 15, no. 11: 5899. https://doi.org/10.3390/app15115899

APA Style

Guzman-Bautista, A., López-Arrabal, A., Sanchez-Oro-Aguado, E., Fernández Gorgojo, A., García-Galán, R., Badesa, F. J., & Vizan-Idoipe, A. (2025). Quasi-Uniform Density Non-Solid Infill Strategy for Axisymmetric Non-Planar Additive Manufacturing. Applied Sciences, 15(11), 5899. https://doi.org/10.3390/app15115899

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