Algorithms for Multilayer Conformal Additive Manufacturing

Despite the rapid advance of additive manufacturing technologies in recent years, methods to fully encase objects with multilayer, thick features are still undeveloped. This issue can be overcome by printing layers conformally about an object’s natural geometry, as opposed to current methods that utilize planar layering. With this mindset, two new methods are derived to generate uniformly distributed layers between initial and desired geometries in both two and three dimensions. The first method is based on variable offset curves and can only be applied to convex or star-convex geometries. The second method is based on manipulated solutions to Laplace’s equation and is applicable to all geometries. Using each method, we present examples of layer generation for several geometries of varying convexities. Results are compared, and the respective advantages and limitations of each method are discussed.