Multi-axis hybrid rapid prototyping using fusion deposition modeling

The objective of this study is to improve prototypes produced by fusion deposition modeling (FDM). FDM, a method of rapid prototyping, produces parts with desirable engineering properties. A new drive and extrusion method for continuous and indefinite deposition of ABS is developed. Process improvements include adding a machining station to tighten tolerances. Research is initiated into 5-axis deposition, which aims to reduce stairstepping errors associated with standard 3-axis deposition. Metrology comparisons to current industry FDM machines are made showing the improvements implemented tighten tolerance ranges, while using a larger nozzle orifice diameter to reduce build times.