Design of complex-geometry parts for multi-axis robotic additive manufacturing technology and its simulation

This thesis presents the design, development, and simulation of complex-geometry parts for multi-axis Robotic Additive Manufacturing (RAM). A Rhino–Grasshopper–KUKA | prc software environment is integrated to generate customized multi-axis toolpaths for geometries that conventional CAD software cannot easily produce. A KUKA KR210 R2700-2 anthropomorphic robot with a positioner is used for simulation, while Altınay Robotics provided an identical robot (without a positioner) for the physical implementation of the generated trajectories. The RAM system is intended for producing intricate geometries using both polymer extrusion and metal deposition. To identify the most suitable method, the study evaluates Wire Arc Additive Manufacturing (WAAM), Wire Laser Additive Manufacturing (WLAM), and Wire-Laser Hybrid Additive Manufacturing (WLHAM) in terms of structural efficiency, deposition quality, and integration feasibility. A multi-color polymer pellet extruder was co-developed with Altınay Robotics and MEF University interns under the supervision of the author and Altınay's mechanical manager, demonstrating multi-material printing. Additionally, an industrial Nolega polymer extruder was procured with MEF BAP research funding for future use. Beyond its technical contributions, this study emphasizes the integration of robotics and additive manufacturing within a unified production workflow. The research adopts a multidisciplinary and collaborative framework, combining engineering, design, and computational modeling to advance manufacturing education and practice. Experimental studies were conducted in collaboration with students from diverse disciplines, fostering hands-on learning and cross-domain knowledge exchange. This integrative approach highlights the thesis as a convergent study bridging theory, practice, and education through robotics-driven digital fabrication. The outcome is a globally competitive RAM technology offering scalable, precise, and sustainable solutions for advanced manufacturing in both engineering and creative fields.