Filling defects, which appear on the tool path ends as the existence of the control precision error of enabling components (laser, nozzle) and movement acceleration and deceleration of moving components, cause serious problems in appearance quality of parts in a number of welding-based rapid prototyping processes such as plasma welding, laser welding, and fused deposition modeling. This paper presents a novel tool path planning algorithm based on endpoint build-in optimization, moving the two path endpoints with filling defects from the part surface into the internal region. Experiments in fused deposition modeling processes show that the algorithm effectively addresses this issue, and is reliable and efficient.
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