Robotic arm-assisted droplet-based additive manufacturing via acoustic levitation: process implementation and experimental optimization

This paper presents the concept, implementation and process optimization of a robotic arm-assisted additive manufacturing system using acoustic levitation for droplet-based deposition of photocurable resin. By integrating acoustic levitation and robotic manipulation, the tank-free material deposition approach has the potential to overcome the limitations inherent in conventional 3D printing - such as fixed build directions, planar layers and the reliance on resin tanks. The focus of this study is on experimental characterization and process optimization. Necessary aspects of implementing the additive manufacturing system were investigated, including the ultraviolet (UV) light profile characterization, resin curing characterization and contact angle measurement. A Taguchi experiment- based process optimization further revealed the optimal combination of process parameters for surface quality on continuously deposited droplets. Implementation of the system was demonstrated using a commercial photocurable resin. This work paves the way for the development of a multi-material contactless and tankless additive manufacturing platform that supports multi-directional deposition.