A thin-wall sphere dome set is manufactured without supports being required using a direct energy deposition additive manufacturing process. A multi-axis tool path combined with a partitioning strategy is utilized. Two partitioning strategies and a rotary toolpath build strategy are applied. The partitioned samples have a 45 mm diameter, and the rotary toolpath sample has a 60 mm diameter. The wall thickness is 2 mm for all case studies. The partitioning strategy provides an opportunity to fabricate geometries without the need for support structures, but it introduces physical properties variations. Large surface irregularities are noticed at the transition points between partitions, which escalates the roughness values drastically in these regions. The surface roughness variations within a build section and across partitions are explored in this paper. Process planning, data collection, and experimental/numerical procedures are developed and implemented to investigate the surface roughness variations (Ra measurement). Two solutions are developed: (i) a destructive testing approach (sections embedded into epoxy) and (ii) a contactless approach. The destructive testing solution uses the magnified pictures of the exposed surface edges of mount samples as input data. The other solution uses a 3D point cloud of the surface. The mount solution results show better accuracy, but the data collection process is time consuming and labour intensive. The destructive test method can detect small textures, while the contactless method is more appropriate for large-scale bead products. This research shows measuring surface roughness is challenging and further development is needed to be developed to be able to effectively measure Ra for AM built components.

使用直接能量沉积添加剂制造工艺可在无需支撑的情况下制造薄壁球形圆顶套件。利用了结合了分割策略的多轴刀具路径。应用了两种分区策略和旋转刀具路径构建策略。分割后的样本直径为45毫米，而旋转刀具路径样本的直径为60毫米。所有案例研究的壁厚均为2 mm。分区策略提供了制造几何结构的机会，而无需支撑结构，但是它引入了物理属性的变化。在隔板之间的过渡点处发现较大的表面不规则度，这在这些区域中使粗糙度值急剧上升。本文探讨了构建区域内和跨分区的表面粗糙度变化。制定并实施了工艺计划，数据收集和实验/数值程序，以研究表面粗糙度变化（Ra测量）。开发了两种解决方案：（i）破坏性测试方法（将部分嵌入环氧树脂中）和（ii）非接触方法。破坏性测试解决方案将安装样本暴露表面边缘的放大图片用作输入数据。另一种解决方案是使用表面的3D点云。安装解决方案的结果显示出更高的准确性，但是数据收集过程既耗时又费力。破坏性测试方法可以检测到较小的纹理，而非接触式方法更适合于大型珠子产品。