Session: 01-03 -01: Advanced Manufacturing and Process–Structure Relationships in Aerospace Structures

Paper Number: 183283

183283 - Process-Property-Performance in Large-Scale Robotic 3D Printing for Aerospace Applications 

Fused deposition modeling (FDM) has gained significant attention in the research and industrial sectors due to its wide applicability. However, conventional gantry-based 3D printers are limited by their restricted degrees of freedom (DOF) and the size of the fabricated structures, prompting researchers to explore alternative solutions for large-scale and complex structure manufacturing. A robotic arm-based 3D printer with 6-Axis presents a promising approach to address these limitations. In this study, a robotic arm-assisted 3D printing system was developed by integrating FDM components with a 6-axis robotic arm. The system’s performance was evaluated by analyzing the mechanical properties of printed samples under varying process parameters, including extruder travel speed (75–125 mm/s), material feed rate (8–13.3 RPM), and extrusion temperature (200–250 °C). Several data-driven models based on measured strength in terms of these process parameters were developed, which accurately predicted the printed samples’ strength based on the selected process conditions. Through experimental parametric studies, the optimized process parameters for high-strength structures were identified as a travel speed of 75–80 mm/s and a feed rate of 10 RPM, producing high-strength samples. The samples’ ultimate strength was also enhanced by increasing the nozzle temperature from 200 °C to 250 °C. In addition to the process parameter optimization, finite element simulations were conducted to investigate the influence of raster orientation (0°/90°, 15°/–75°, 30°/–60°, and 45°/–45°) on the mechanical and fracture response of 3D-printed composites. The simulation results revealed that samples printed with a 45°/–45° raster pattern exhibited the highest fracture resistance and bending strength, followed by 30°/–60°, 15°/–75°, and 0°/90° orientations. This trend was attributed to the superior load transfer capability and interlayer bonding efficiency in the ±45° configurations. The combined experimental and simulation studies demonstrate that the mechanical performance of robotic arm–based FDM parts can be significantly improved by optimizing both printing parameters and raster orientations. This study highlights the potential of robotic arm–based 3D printing to overcome the limitations of traditional systems and provides a foundation for further advancements in large-scale, high-strength composite structure manufacturing for aerospace and advanced engineering applications.

[1] Anorb Das, 'Understanding Influence of Robotic Fused Deposition Parameters on Polymer Composite Performance', Master Thesis, School of Mechanical and Aerospace Engineering, Oklahoma State University, 2025

Presenting Author: Wei Zhao Oklahoma State University

Presenting Author Biography: Dr. Wei Zhao is currently an Assistant Professor in Mechanical and Aerospace Engineering at Oklahoma State University, Stillwater, OK. He earned his PhD in Aerospace Engineering at Virginia Tech (Blacksburg, VA). Dr. Zhao has a wide range of research interests in structures and materials, aeroelasticity, and multidisciplinary design optimization. Dr. Zhao is a senior member of of AIAA. He is an elected member of both AIAA Structures Technical Committee and ASME Structure Material Technical Committee. He is recipient of AIAA Abe Zarem Educator Award and AIAA Structures Best Paper Award 2024.