Additive Manufacturing Path Planning for Multi-Tool Part Fabrication
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Solution Overview
Problem
Conventional additive manufacturing systems require manual operator intervention to determine the manufacturing path and process for complex parts, lacking automation in planning and execution.
Innovation Solution
An additive manufacturing system that autonomously plans a manufacturing path and sequence using a processing circuit, sensor data, and three-dimensional models to control multiple tools and processes, including arc welding and laser welding, based on the part's features and system capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual operator intervention is used to determine manufacturing path and process, then flexibility in handling complex parts is maintained, but automation level and manufacturing efficiency deteriorate
Solution Approach 1:
The system performs self-planning by automatically analyzing the three-dimensional model of the part, identifying features, selecting appropriate additive manufacturing processes, and generating the manufacturing path without external operator intervention. The processing circuit autonomously executes the entire path planning sequence based on stored instructions and sensor data.
Solution Approach 2:
The patent replaces manual operator decision-making with an automated computational system. The processing circuit uses algorithms to analyze geometric data, determine manufacturing parameters, and generate toolpaths, substituting human cognitive processes with automated information processing.
2Productivity
If automated path planning is implemented, then manufacturing efficiency and precision improve, but system complexity and computational requirements increase
Solution Approach 1:
The system performs preliminary analysis of the part geometry and manufacturing requirements before actual manufacturing begins. The processing circuit pre-determines the entire manufacturing sequence, tool selection, and path parameters, allowing the physical manufacturing process to proceed without real-time decision delays.
Solution Approach 2:
The system creates a digital representation (three-dimensional model) of the part to be manufactured and performs all planning operations on this digital copy. This virtual modeling allows complex computations to be performed without affecting the physical manufacturing system, isolating computational complexity from physical system complexity.
3Adaptability or versatility
If multiple additive manufacturing tools and processes are integrated, then manufacturing versatility and part quality improve, but control complexity and coordination difficulty increase
Solution Approach 1:
The system is designed to handle multiple additive manufacturing processes (such as material extrusion, selective laser sintering, directed energy deposition) through a single integrated processing circuit. The same control system can select and coordinate different tools and processes based on the specific features identified in the part model, making the system universally applicable to various manufacturing scenarios.
Solution Approach 2:
The manufacturing process is divided into discrete segments or features that can be independently analyzed and assigned to appropriate tools. The processing circuit breaks down the complex manufacturing task into smaller sub-tasks, each handled by specific additive manufacturing tools, making coordination more manageable.
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.