Date of Submission
Master of Science in Mechanical Engineering
Mechanical and Industrial Engineering
Omar Faruk Emon, Ph.D.
Cheryl Li, Ph.D.
Sumith Yesudasan, Ph.D.
Additive manufacturing, 3D Printing, Non-planar, Thermoset Pre-polymer
Additive manufacturing, Three-dimensional printing, Polymers--Research
Additive manufacturing or three-dimensional (3D) printing is an advanced process of manufacturing that challenges traditional manufacturing methodologies. However, the current 3D printing process does exhibit specific limitations. It generates printing paths that are in a horizontal plane, proving inadequate for printing curved or non-flat structures. This study established a printing procedure capable of simultaneously executing printing in X, Y, and Z directions. The limitations posed by conventional 3D printing lead to the poor surface quality of curved printed objects. In contrast, non-planar 3D printing provides smoother surfaces. This work developed a program capable of producing non-planar print paths for the fabrication of curved surfaces. Non-planar 3D printing is set to have a crucial role in the fabrication of curved features.
An innovative approach to 3D printing thermoset pre-polymers, substances capable of transitioning from liquid to solid states under specific conditions, was explored. The technique involved the precise deposition of these pre-polymers in a controlled manner, allowing 3D printing on curved surfaces. The properties of the thermoset pre-polymer material used for 3D printing were explored. The print material and the program developed were utilized to print on complex curved surfaces. In conventional 3D printing, certain objects require temporary support during 3D printing, which can be later eliminated. The developed program is tested for the 3D printing of support-free structures. To demonstrate the capabilities of the developed program, a structure on a scaled model of a human palm and a non-planar support-free structure is printed. Additionally, an optimized iteration of the program is developed to reduce the calculation time and speed up the g-code generation.
Abid Ali, Junaid, "Non-planar 3D Printing of Thermosetting Prepolymers" (2023). Master's Theses. 202.
Available for download on Friday, December 05, 2025