A review of geometry representation and processing methods for cartesian and multiaxial robot-based additive manufacturing

Abstract

Nowadays, robot-based additive manufacturing (RBAM) is emerging as a potential solution to increase manufacturing flexibility. Such technology allows to change the orientation of the material deposition unit during printing, making it possible to fabricate complex parts with optimized material distribution. In this context, the representation of parts geometries and their subsequent processing become aspects of primary importance. In particular, part orientation, multiaxial deposition, slicing, and infill strategies must be properly evaluated so as to obtain satisfactory outputs and avoid printing failures. Some advanced features can be found in commercial slicing software (e.g., adaptive slicing, advanced path strategies, and nonplanar slicing), although the procedure may result excessively constrained due to the limited number of available options. Several approaches and algorithms have been proposed for each phase and their combination must be determined accurately to achieve the best results. This paper reviews the state-of-the-art works addressing the primary methods for the representation of geometries and the subsequent geometry processing for RBAM. For each category, tools and software found in the literature and commercially available are discussed. Comparison tables are then reported to assist in the selection of the most appropriate approaches. The presented review can be helpful for designers, researchers and practitioners to identify possible future directions and open issues.

Robotic additive manufacturing by laser metal deposition in the context of industry 4. 0

“…A integração entre os processos de manufatura aditiva e robótica culminou na concepção de células robóticas dedicadas à deposição metálica com LMD. Conforme destacado por Lettori et al (2022), a manufatura aditiva baseada em robôs (RBAM) está emergindo como uma solução altamente promissora para aprimorar a flexibilidade nos processos de manufatura. A orientação da peça, a deposição multiaxial e as estratégias de fatiamento e preenchimento devem ser cuidadosamente consideradas a fim de assegurar resultados satisfatórios e evitar falhas na impressão.…”

Design and analysis of a 4-axis cartesian robot for unloading plastic injection machines in industrial applications

“…The contemporary development of production systems has been influenced by innovative techniques [1]. This development has been closely aligned with the widespread adoption of lean manufacturing practices [2], flexible manufacturing systems [3], Cartesian robots [4], as well as methodologies like layered production techniques [5], digital mirroring [6], and factory simulation [7]. These approaches have enabled the production of complex products with low tolerances [8].…”

Non-Uniform Planar Slicing for Robot-Based Additive Manufacturing

“…The process parameters are adapted according to the required layer thickness, considering the minimum and maximum thickness limits of the printing device. Figure 1: a) Staircase effect, taken from [10]; b) Adaptive planar slicing, taken from [19]; c) Adaptive planar slicing, taken from [13].…”

“…For example, an extruder for plastic material [23] or a welding torch [17] can be attached to a robot arm. These solutions are used to increase the manufacturing flexibility of cartesian AM [10], enabling the deposition of material in multiple directions. Moreover, nonplanar [3] and non-uniform thickness [25] slicing can be realized.…”

“…The possibility of a variable thickness in the layer extension allows much expanded manufacturing options, possibly leading to a reduction of the total number of layers, the support volume, and manufacturing time, also increasing the surface finish and mechanical performances of the final product [8]. Even if support structures may be still required for some portions [10], their complete absence becomes feasible.…”