AM Build Layout Using Toolpath Volumes for Batch Post-Machining
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Solution Overview
Problem
Existing additive manufacturing (AM) processes face inefficiencies due to the need for high-density object layouts that obstruct post-manufacturing processes, requiring time-consuming individual fixing and processing of objects, which reduces productivity and efficiency.
Innovation Solution
A build file generator determines an optimal layout and sequence for objects on a substrate, considering toolpath volumes to allow simultaneous post-manufacturing processes while objects remain fixed, maximizing density and minimizing collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-density object layouts are used to maximize substrate utilization, then manufacturing productivity increases, but post-manufacturing processes become obstructed requiring individual removal and fixing of objects
Solution Approach 1:
The patent applies preliminary action by determining the post-manufacturing toolpath volumes before generating the build file, and using this information to optimize the object layout on the substrate. The system calculates the space required for post-manufacturing tools to access each object, then arranges objects to maximize density while ensuring toolpath accessibility, eliminating the need for individual removal and fixing operations.
2Manufacturing precision
If objects are individually removed and fixed for post-manufacturing processes, then processing precision is maintained, but total production time increases
Solution Approach 1:
The patent merges multiple individual post-manufacturing operations into a single batch process by maintaining objects on the substrate throughout post-manufacturing. The system enables multiple objects to be processed simultaneously or in sequence without removal, combining what would otherwise be separate handling operations into one continuous workflow, thereby reducing total production time while maintaining precision through controlled toolpaths.
3Ease of operation
If objects are arranged with sufficient spacing for post-manufacturing access, then toolpath accessibility is ensured, but substrate utilization efficiency decreases
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting object positions and orientations on the substrate based on calculated toolpath volumes. The system optimizes the spatial parameters of object placement to achieve the maximum density configuration that still allows post-manufacturing tools to access all objects, thereby resolving the trade-off between spacing requirements and substrate utilization efficiency.
4Productivity
If complex layout optimization is performed to maximize object density, then manufacturing efficiency increases, but computational complexity and processing time increase
Solution Approach 1:
The patent performs preliminary calculation of toolpath volumes for all objects before generating the final layout. By pre-determining the space requirements for post-manufacturing operations, the system simplifies the subsequent layout optimization problem, reducing computational complexity while still achieving high-density arrangements that maximize manufacturing efficiency.
Data Source
AI summary
Methods and apparatus for optimally positioning objects for automated machining are described herein. An example build file generator described herein includes an object file manager to identify a first toolpath volume associated with a first object to be formed via an additive manufacturing (AM) process. The first toolpath volume is based on a first toolpath of a first post-manufacturing process to be used on the first object. The object file manager is also to identify a second toolpath volume associated with a second object to be formed via the AM process. The second toolpath volume is based on a second toolpath of a second post-manufacturing process to be used on the second object. The example build file generator also includes a layout determiner to determine a layout of the first and second objects to be formed on a substrate by the AM process based on the first and second toolpath volumes.