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<p>This study investigates the application of Laser Additive Manufacturing–Directed Energy Deposition (LAM-DED) for the fabrication of a thin-walled hemispherical dome, a geometry characterized by continuous curvature and challenging overhang conditions. Initially, the dome was fabricated using a conventional 3-degree-of-freedom (3-DOF) fused deposition modelling (FDM) system, where support structures were required due to limitations in planar layer deposition. In contrast, a 5-degree-of-freedom (5-DOF) LAM-DED system enabled support-free fabrication through adaptive toolpath orientation and multi-axis deposition strategies. A comparative volumetric analysis demonstrated a material reduction of 49.35% in the 5-DOF configuration relative to the 3-DOF approach, highlighting improved manufacturing efficiency. The resulting process optimization framework confirms the robustness and effectiveness of the 5-DOF LAM-DED configuration in achieving high-quality fabrication. The findings highlight the potential of multi-axis LAM-DED systems to enhance material efficiency, reduce waste, and support sustainable manufacturing practices. Future work will explore the integration of 6-DOF robotic systems to further expand geometric capabilities and process adaptability.</p>

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Process Parameter Optimization for Sustainable Manufacturing of Thin-Walled Hemispherical Domes Utilizing 3-DOF & 5-DOF Deposition Techniques

  • 期刊论文

  • 发表日期：

    2026年5月29日

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  • Ashish Tripathi,
  • Shiv Manjaree Gopaliya,
  • Christ P. Paul

摘要

This study investigates the application of Laser Additive Manufacturing–Directed Energy Deposition (LAM-DED) for the fabrication of a thin-walled hemispherical dome, a geometry characterized by continuous curvature and challenging overhang conditions. Initially, the dome was fabricated using a conventional 3-degree-of-freedom (3-DOF) fused deposition modelling (FDM) system, where support structures were required due to limitations in planar layer deposition. In contrast, a 5-degree-of-freedom (5-DOF) LAM-DED system enabled support-free fabrication through adaptive toolpath orientation and multi-axis deposition strategies. A comparative volumetric analysis demonstrated a material reduction of 49.35% in the 5-DOF configuration relative to the 3-DOF approach, highlighting improved manufacturing efficiency. The resulting process optimization framework confirms the robustness and effectiveness of the 5-DOF LAM-DED configuration in achieving high-quality fabrication. The findings highlight the potential of multi-axis LAM-DED systems to enhance material efficiency, reduce waste, and support sustainable manufacturing practices. Future work will explore the integration of 6-DOF robotic systems to further expand geometric capabilities and process adaptability.