Additive Manufacturing Path Planning for Automated Feature-Based Deposition
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Solution Overview
Problem
Conventional additive manufacturing systems require manual operator intervention to determine the path and processes for manufacturing parts, which can be inefficient and prone to errors due to the need to select appropriate additive manufacturing processes and parameters for various features of a part.
Innovation Solution
A system and method that utilize a processing circuit and machine-readable instructions to receive a three-dimensional model of a part, determine a sequence of additive manufacturing processes based on the model, available tools, and motion capabilities, and control the tools to manufacture the part automatically, incorporating sensor data and various welding-type processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual operator intervention is used to determine path and processes, then flexibility in handling complex part features is improved, but productivity and manufacturing efficiency deteriorate
Solution Approach 1:
The additive manufacturing system automatically determines the manufacturing path and selects appropriate processes for different part features without manual operator intervention. The system analyzes the three-dimensional model, identifies features such as holes and slots, and autonomously plans deposition paths, thereby maintaining flexibility while improving productivity.
Solution Approach 2:
The patent replaces manual operator decision-making with an automated control system that uses algorithms to analyze part geometry and select manufacturing parameters. The control system substitutes human intelligence with computational algorithms that can process three-dimensional models and determine optimal manufacturing paths automatically.
2Adaptability or versatility
If manual operator intervention is used to select processes and parameters, then adaptability to various part features is improved, but manufacturing precision and consistency deteriorate due to human error
Solution Approach 1:
The system incorporates feedback mechanisms where the control system continuously monitors the manufacturing process, compares actual results with planned parameters, and makes real-time adjustments. This ensures consistent and accurate manufacturing across different part features while maintaining adaptability to various geometries.
Solution Approach 2:
The automated system consistently applies the same analytical algorithms and decision-making rules to all part features, eliminating variability introduced by human operators. The system autonomously selects processes and parameters based on objective criteria derived from the three-dimensional model, ensuring repeatable and precise manufacturing results.
3Productivity
If automated path planning is implemented, then productivity and efficiency are improved, but device complexity increases
Solution Approach 1:
The control system is designed to perform multiple functions: analyzing three-dimensional models, identifying part features, planning deposition paths, selecting manufacturing processes, and controlling additive manufacturing tools. By consolidating these functions into a single multi-functional system, the patent improves productivity while managing device complexity through integration rather than proliferation of separate components.
Data Source
AI summary
Disclosed are systems and methods to plan a path to form a part using an additive manufacturing system. The additive manufacturing system may include one or more additive manufacturing tools. The additive manufacturing tools may include arc welding tools and non-arc welding tools. The system may also manufacture the part based on the planned path.