Interleaved Toolpath Planning for Hybrid Part Fabrication
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Solution Overview
Problem
Determination of toolpaths for part fabrication, especially combined additive and subtractive techniques, is complex and time-consuming, leading to inefficiencies in fabrication processes.
Innovation Solution
A method and system for automated toolpath generation that includes receiving a virtual part, modifying it for fabrication, determining efficient toolpaths, and generating machine instructions for both additive and subtractive processes, using a system with deposition, material removal, and movement mechanisms controlled by a computing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated toolpath generation is implemented, then fabrication efficiency is improved, but system complexity increases
Solution Approach 1:
The system segments the fabrication process into distinct additive and subtractive operations, with separate toolpath generation algorithms for each. This modular approach manages complexity by handling different fabrication techniques independently while coordinating them through a unified system architecture.
Solution Approach 2:
A computing system acts as an intermediary between the digital model and physical fabrication processes. This intermediary automatically generates toolpaths, coordinates deposition and material removal operations, and manages the complex interactions between different fabrication mechanisms without requiring manual intervention.
2Device complexity
If manual toolpath determination is used, then system complexity is reduced, but fabrication time increases
Solution Approach 1:
The system performs self-service by automatically generating its own toolpaths without external human intervention. The computing system analyzes the digital model, determines optimal deposition and material removal sequences, and produces fabrication instructions autonomously, eliminating time-consuming manual toolpath creation.
Solution Approach 2:
The system performs preliminary action by pre-calculating and optimizing toolpaths before fabrication begins. All path planning, parameter optimization, and operation sequencing are completed in advance through automated computation, enabling efficient execution during the actual fabrication process.
3Manufacturing precision
If combined additive and subtractive techniques are used, then manufacturing precision is improved, but process complexity increases
Solution Approach 1:
The system merges additive deposition and subtractive material removal into a unified fabrication process. By integrating both operations in a single coordinated system with unified toolpath generation, it achieves high manufacturing precision through the complementary strengths of both techniques while managing process complexity through integration.
Solution Approach 2:
The system applies local quality by selecting specific deposition or removal operations for different regions of the part based on local requirements. The automated toolpath generation identifies areas needing additive fabrication versus subtractive finishing, applying the appropriate technique locally to optimize overall manufacturing precision.
4Loss of substance
If automated toolpath generation is implemented, then material efficiency is improved, but computational requirements increase
Solution Approach 1:
The system uses feedback mechanisms in its automated toolpath generation, analyzing the digital model and fabrication constraints to optimize material usage. The computing system calculates efficient deposition paths and material removal sequences that minimize waste, with the computational energy invested yielding significant reductions in material loss.
Data Source
AI summary
A method for facilitating part fabrication, such as by automated toolpath generation, can include one or more of: receiving a virtual part; modifying the virtual part; and/or determining toolpaths to fabricate the target part. The toolpaths preferably define an ordered series of additive and subtractive toolpaths, more preferably wherein the additive and subtractive toolpaths are interleaved, which can function to achieve high manufacturing efficiency and/or performance. The method can additionally or alternatively include: generating machine instructions based on the toolpaths; fabricating the target part based on the machine instructions; calibrating the fabrication system; and/or any other suitable elements.