Algorithms for Multilayer Conformal Additive Manufacturing

Despite the rapid advance of additive manufacturing (AM) 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 boundary, as opposed to current methods that utilize planar layering. With this mindset, two methods are derived to generate layers between the boundaries of initial and desired geometric objects in both two and three dimensions. The first method is based on variable offset curves (VOCs) and is applicable to pairs of initial and desired geometric objects that satisfy mild compatibility conditions. In this method, layers are generated by uniformly partitioning each of the normal line segments emanating from the initial object boundary and intersecting the desired object. The second method is based on manipulated solutions to Laplace's equation and is applicable to all geometric objects. Using each method, we present examples of layer generation for several objects of varying convexities. Results are compared, and the respective advantages and limitations of each method are discussed.