Enhancing Extrusion Precision and Reliability in Robotic Multi-Axis Additive Manufacturing through Digital Twin Integration

In robotic multi-axis additive manufacturing, achieving high precision and consistency is crucial. This paper presents a comprehensive calibration procedure and optimization strategy for process parameters in a filament-based extruder mounted on an industrial robot. A digital twin of the manufacturing setup is utilized to simulate and validate the process, enabling precise adjustments and automation of code generation for robotic operations. Experimental calibration artifacts are produced and measured to verify the effectiveness of the proposed approach, highlighting the impact of variables such as hot-end temperature, layer height, and tool center point velocity on print quality. A laser tracker is employed to ensure precise measurement of calibration artifacts, enhancing the accuracy of the calibration process. The results highlight the potential for advancements in the precision and reliability of multi-axis additive manufacturing processes through systematic calibration and optimization, enabling the stable production of complex 3D-printed structures and reduced production waste.