Freeform 3D Printing

Most additive manufacturing technologies such as 3D printing utilize support materials in the fabrication process. Beyond the technical challenges of support removal these materials are wasteful – increasing fabrication and processing time while impacting quality. This tool presents “Freeform Printing”, a novel design approach for 3D printing without additional auxiliary structures. A 6-axis KUKA robotic arm is repurposed as a 3D printing platform onto which custom-designed thermoplastic extruders are attached. We demonstrate freeform extrusion using a round nozzle attached to an active air-cooling unit, which solidifies the material upon extrusion. In addition, we present a method for printing geometrically complex structures using a multi-strand extrusion nozzle. These experiments represent a sustainable approach to additive manufacturing and digital fabrication at large, and point towards new possible directions in sustainable manufacturing.