This research developed a CAM S/W, which generates an adaptive 5-axis tool path, to optimize the quality of Direct Energy Deposition (DED) 3D printing. After reconstructing part shapes and generating printing paths in each shape, the path simulation including automatic collision detection was implemented. Productivity and printing quality were improved through equipment improvement and process optimization. In addition, high-quality parts with desirable physical and mechanical properties were produced by generating an adaptive 5-axis path specialized in the printing process that reflects various physical phenomena and monitoring results. Finally, the performance of CAM S/W was verified through the production of prototypes for industrial components.

High-accuracy micropatterns such as V-shaped microgrooves are increasingly in demand for various engineering areas. And the technical trend goes for large surface areas in precision machining technology. So micropatterns with large surface areas are expected to play an increasingly important role in today’s manufacturing technology. In this study, we focused on developing machining technologies. First, a machine vision system for precise tool setting is developed. Second, an on-machine measurement (OMM) system for large-area measurement is implemented. And also software for tool path generation and simulation is developed. With these technologies we fabricated large-surface micropatterns in an electroless nickel-plated workpiece with single-crystal diamond tools and a 32-in, ㎜ ㎜ 450 675 × mold with tens of V-and pyramid-shaped micropatterns.