Additive Manufacturing Layout Planning for Toolpath-Cleared Machining
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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 post-manufacturing processes that require space around objects for toolpaths, leading to reduced efficiency and productivity, as objects often need to be spaced apart to accommodate post-processing tools, which decreases the number of objects that can be built in a batch.
Innovation Solution
A build file generator determines an optimal layout for multiple objects on a substrate based on toolpath volumes associated with each object, allowing objects to be positioned closely while still enabling post-manufacturing processes by defining a sequence that clears toolpath volumes for subsequent objects, thus enabling high-density object layouts without the need for individual object removal and fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If objects are spaced apart to accommodate post-processing toolpaths, then post-manufacturing processes can be performed, but the layout density decreases and productivity is reduced
Solution Approach 1:
The system performs preliminary planning of post-manufacturing operations during the build file generation phase. By identifying toolpath volumes in advance and arranging objects to accommodate these volumes before actual manufacturing, the system enables both high-density layouts and post-processing accessibility without requiring objects to be spaced apart during the build process.
Solution Approach 2:
The system transitions from two-dimensional layout planning to three-dimensional toolpath volume consideration. By evaluating the spatial extent of post-processing toolpaths in 3D space and arranging objects based on these volumetric constraints, the system achieves optimal density while maintaining manufacturing accessibility.
2Productivity
If objects are arranged in high-density layouts, then productivity increases, but post-manufacturing processes become difficult to perform
Solution Approach 1:
The system performs preliminary planning of post-manufacturing operations during the build file generation phase. By identifying toolpath volumes in advance and arranging objects to accommodate these volumes before actual manufacturing, the system enables both high-density layouts and post-processing accessibility without requiring objects to be spaced apart during the build process.
Solution Approach 2:
The system transitions from two-dimensional layout planning to three-dimensional toolpath volume consideration. By evaluating the spatial extent of post-processing toolpaths in 3D space and arranging objects based on these volumetric constraints, the system achieves optimal density while maintaining manufacturing accessibility.
3Ease of manufacture
If objects are removed from substrate for post-processing, then post-manufacturing processes can be performed, but time and complexity increase
Solution Approach 1:
The system merges the substrate with multiple objects into a single integrated assembly that is processed together. By enabling post-manufacturing operations to be performed on the substrate with objects still attached, the system eliminates the time-consuming steps of individual object removal and reattachment, while the build file generator ensures proper spatial arrangement for toolpath clearance.
Data Source
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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.