A Generic Geometric Code-Parsing Framework for Corner Optimization in Curved-Surface Directed Energy Deposition

TL;DR

This paper introduces a new method to improve the quality of curved-surface 3D printing by optimizing toolpaths to reduce defects at corners.

Contribution

A novel geometric code-parsing framework for corner optimization in curved-surface additive manufacturing is proposed.

Findings

The method suppresses corner overbuild and morphological distortion in curved-surface deposition.

It improves dimensional consistency and surface quality without altering the CAD model or slicing workflow.

The strategy is scalable and applicable for high-precision industrial additive manufacturing.

Abstract

Laser-cladding directed energy deposition enables both the repair and fabrication of complex metallic components with curved surfaces. However, during multi-axis deposition on curved substrates, sharp transient feed-rate fluctuations at corner segments—together with an approximately constant powder feed rate—readily cause local over-deposition and geometric defects (e.g., nodules and humps). These defects compromise surface-profile fidelity, thereby creating a major barrier to practical deployment. To overcome this limitation, we propose a corner-oriented path-optimization strategy based on geometric code parsing. By operating directly on the toolpath without modifying the Computer-Aided Design model or slicing workflow, the proposed method suppresses corner overbuild and associated morphological distortion in curved-surface directed energy deposition, substantially improving dimensional consistency and surface quality. Overall, this strategy provides a scalable and broadly applicable route toward high-precision, high-reliability, industrial-scale curved-surface additive manufacturing.

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