AM Object Layout Using Toolpath Volumes for Dense Post-Processing
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Solution Overview
Problem
In additive manufacturing, achieving high-density object layouts on a substrate is challenging due to the need for space around objects to accommodate post-manufacturing toolpaths, which reduces efficiency and productivity, as objects often require individual processing and fixing to machines, especially those with complex geometries that lack suitable fixture points.
Innovation Solution
A build file generator that determines an optimal layout for multiple objects on a substrate based on toolpath volumes associated with each object, allowing objects to be positioned partially within each other's toolpath volumes, enabling simultaneous machining while attached to the substrate by defining a sequence of post-manufacturing processes and removals to avoid collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If objects are arranged with sufficient spacing to accommodate post-manufacturing toolpaths, then collision-free machining is achieved, but substrate utilization density decreases
Solution Approach 1:
The system performs preliminary analysis of toolpath volumes during build file generation, identifying objects whose toolpaths will not collide before manufacturing begins. This allows objects to be positioned closer together on the substrate while ensuring collision-free post-manufacturing operations through pre-planned sequences.
Solution Approach 2:
The system dynamically determines processing sequences based on object positions and toolpath volumes. Objects are processed in optimized sequences that allow closer spacing on the substrate, with the processing order adapting to the specific geometric relationships and toolpath requirements of each object batch.
2Manufacturing precision
If objects with complex geometries are processed individually with dedicated fixing, then machining precision is maintained, but processing time and operational complexity increase
Solution Approach 1:
The system merges multiple objects into batches that can be processed simultaneously on the same substrate. Objects with complex geometries are grouped with other objects in optimized sequences, eliminating the need for individual fixing and processing while maintaining machining precision through controlled toolpath planning.
Solution Approach 2:
The substrate serves multiple functions: it acts as both the manufacturing platform for additive manufacturing and the processing platform for post-manufacturing operations. This multi-functionality allows objects to remain on the substrate throughout both manufacturing and post-processing, eliminating transfer and re-fixing operations.
3Productivity
If objects are positioned to maximize substrate utilization, then productivity increases, but toolpath collision risk increases
Solution Approach 1:
The system incorporates feedback loops that analyze object positions, toolpath volumes, and potential collisions during build file generation. The layout determination uses this feedback to optimize object spacing and processing sequences, achieving high substrate utilization while eliminating toolpath collision risks through iterative refinement.
Solution Approach 2:
The build file generator acts as an intermediary that mediates between object layout requirements and toolpath collision constraints. It processes geometric data, calculates toolpath volumes, and determines optimal processing sequences that allow dense object packing while preventing collisions through intelligent sequencing.
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.