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浙江大学学报(工学版)
Journal of ZheJiang University (Engineering Science)  2025, Vol. 59 Issue (7): 1333-1343    DOI: 10.3785/j.issn.1008-973X.2025.07.001
    
Optimization methods of 3D self-supporting truss structure based on muti-axis 3D printing
Jun YE1,2(),Zhibin XIAO2,3,Xiaoyang LIN1,Guan QUAN1,Zhen WANG4,Yueda WANG1,Jiangfei HE6,Yang ZHAO5
1. College of Civil Engineering and Architecture, Zhejiang University, Hangzhou 310058, China
2. Center for Balance Architecture, Zhejiang University, Hangzhou 310028, China
3. The Architectural Design & Research Institute of Zhejiang University Limited Company, Hangzhou 310028, China
4. Department of Civil Engineering, Hangzhou City University, Hangzhou 310015, China
5. School of Civil Engineering, Shaoxing University, Shaoxing 312000, China
6. China Energy Engineering Group Zhejiang Electric Power Design Institute Limited Company, Hangzhou 310012, China
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Abstract  

A two-step optimization method based on multi-axis 3D printing was proposed, as the three-axis optimization method has limitations in 3D printing angles and material efficiency, leading to material waste. The design domain was divided into several partitions, and the local printing direction of each partition was solved optimally to maximize the printability of the structure. When the printability index was below the set threshold, the printability of the structure was improved by simultaneously optimizing the structural mechanical properties and the local printing directions to plan the printing path. The effectiveness of the proposed method was verified through several arithmetic examples. Results show that compared with the traditional three-axis printing algorithm, the proposed method fully utilizes the flexibility of multi-axis 3D printing, achieving less material volume increase, better design outcomes of the printed structure, and a significant improvement in the printability of the structure.

Key words： multi-axis 3D printing      structure optimization      self-supporting structures      printing path planning      printability index     
Received: 15 May 2024      Published: 25 July 2025
CLC:  TU 311.4  
Fund:  国家自然科学基金资助项目（52208215，52078452）；浙江省基础公益研究计划资助项目（LGG22E080005，LQ22E080008）.
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Jun YE
Zhibin XIAO
Xiaoyang LIN
Guan QUAN
Zhen WANG
Yueda WANG
Jiangfei HE
Yang ZHAO
Cite this article:

Jun YE,Zhibin XIAO,Xiaoyang LIN,Guan QUAN,Zhen WANG,Yueda WANG,Jiangfei HE,Yang ZHAO. Optimization methods of 3D self-supporting truss structure based on muti-axis 3D printing. Journal of ZheJiang University (Engineering Science), 2025, 59(7): 1333-1343.

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https://www.zjujournals.com/eng/10.3785/j.issn.1008-973X.2025.07.001     OR     https://www.zjujournals.com/eng/Y2025/V59/I7/1333


基于多轴3D打印的三维自支撑桁架结构优化方法

三轴优化方法在3D打印角度和材料效率方面存在局限性，造成材料浪费，为此提出基于多轴3D打印的两步优化方法. 将设计域划分成若干分区，优化求解各分区的局部打印方向，使结构尽可能被打印. 当可打印性指标低于设定阈值时，同时优化结构力学性能和局部打印方向来规划打印路径，使结构的可打印性提升. 设置多个算例，验证所提方法的有效性. 结果表明，相比传统的三轴打印算法，所提方法能够充分利用多轴3D打印的灵活性，使材料体积增加更少，打印结构设计结果更优，结构的可打印性得到有效提升.


关键词： 多轴3D打印,  结构优化,  自支撑结构,  打印路径规划,  可打印性指标 
Fig.1 Workflow of layout and geometry optimization
Fig.2 Diagram of member printing direction identification
Fig.3 Diagram of design domain partition
Fig.4 Diagram of local printing direction projection
Fig.5 Suspension violation value of projection surface
Fig.6 Print surface continuity constraints
Fig.7 Projection of printing turning angle
Fig.8 Influence of boundary position variables of partitions in same layer on optimization process
Fig.9 Flow chart of optimization method for self-supporting truss structures based on multi-axis 3D printing
Fig.10 Effect of structure overhang angle on print quality
Fig.11 Collision problem for multi-axis printing
Fig.12 Optimization results of rotating cantilever arithmetic example
Fig.13 Printing slicing path of rotating cantilever
Fig.14 Optimization results of cantilever arithmetic example
Fig.15 Optimization results of two-load truss arithmetic example
Fig.16 Multi-axis printing system
Fig.17 Slicing process for printing models
Fig.18 Photos of model printing process
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