Toward better build volume packing in additive manufacturing: classification of existing problems and benchmarks

In many cases, the efficient operation of Additive Manufacturing (AM) technology relies on build volumes being packed effectively. Packing algorithms have been developed in response to this requirement. The configuration of AM build volumes is particularly challenging due to the multitude of irregular geometries encountered and the potential benefits of nesting parts. Currently proposed approaches to address this packing problem are routinely evaluated on data sets featuring shapes that are not representative of targeted manufacturing products. This study provides a useful classification of AM build volume packing problems and an overview of existing benchmarks for the analysis of such problems. Additionally, this paper discusses characteristics of future, more realistic, benchmarks with the intention of promoting research toward effective and efficient AM build volume packing being integrated into AM production planning methodologies

Toward better build volume packing in additive manufacturing: classification of existing problems and benchmarks

In many cases, the efficient operation of Additive Manufacturing (AM) technology relies on build volumes being packed effectively. Packing algorithms have been developed in response to this requirement. The configuration of AM build volumes is particularly challenging due to the multitude of irregular geometries encountered and the potential benefits of nesting parts. Currently proposed approaches to address this packing problem are routinely evaluated on data sets featuring shapes that are not representative of targeted manufacturing products. This study provides a useful classification of AM build volume packing problems and an overview of existing benchmarks for the analysis of such problems. Additionally, this paper discusses characteristics of future, more realistic, benchmarks with the intention of promoting research toward effective and efficient AM build volume packing being integrated into AM production planning methodologies

Development and Integration of Geometric and Optimization Algorithms for Packing and Layout Design

The research work presented in this dissertation focuses on the development and application of optimization and geometric algorithms to packing and layout optimization problems. As part of this research work, a compact packing algorithm, a physically-based shape morphing algorithm, and a general purpose constrained multi-objective optimization algorithm are proposed. The compact packing algorithm is designed to pack three-dimensional free-form objects with full rotational freedom inside an arbitrary enclosure such that the packing efficiency is maximized. The proposed compact packing algorithm can handle objects with holes or cavities and its performance does not degrade significantly with the increase in the complexity of the enclosure or the objects. It outputs the location and orientation of all the objects, the packing sequence, and the packed configuration at the end of the packing operation. An improved layout algorithm that works with arbitrary enclosure geometry is also proposed. Different layout algorithms for the SAE and ISO luggage are proposed that exploit the unique characteristics of the problem under consideration. Several heuristics to improve the performance of the packing algorithm are also proposed. The proposed compact packing algorithm is benchmarked on a wide variety of synthetic and hypothetical problems and is shown to outperform other similar approaches. The physically-based shape morphing algorithm proposed in this dissertation is specifically designed for packing and layout applications, and thus it augments the compact packing algorithm. The proposed shape morphing algorithm is based on a modified mass-spring system which is used to model the morphable object. The shape morphing algorithm mimics a quasi-physical process similar to the inflation/deflation of a balloon filled with air. The morphing algorithm starts with an initial manifold geometry and morphs it to obtain a desired volume such that the obtained geometry does not interfere with the objects surrounding it. Several modifications to the original mass-spring system and to the underlying physics that governs it are proposed to significantly speed-up the shape morphing process. Since the geometry of a morphable object continuously changes during the morphing process, most collision detection algorithms that assume the colliding objects to be rigid cannot be used efficiently. And therefore, a general-purpose surface collision detection algorithm is also proposed that works with deformable objects and does not require any preprocessing. Many industrial design problems such as packing and layout optimization are computationally expensive, and a faster optimization algorithm can reduce the number of iterations (function evaluations) required to find the satisfycing solutions. A new multi-objective optimization algorithm namely Archive-based Micro Genetic Algorithm (AMGA2) is presented in this dissertation. Improved formulation for various operators used by the AMGA2 such as diversity preservation techniques, genetic variation operators, and the selection mechanism are also proposed. The AMGA2 also borrows several concepts from mathematical sciences to improve its performance and benefits from the existing literature in evolutionary optimization. A comprehensive benchmarking and comparison of AMGA2 with other state-of-the-art optimization algorithms on a wide variety of mathematical problems gleaned from literature demonstrates the superior performance of AMGA2. Thus, the research work presented in this dissertation makes contributions to the development and application of optimization and geometric algorithms

Genetic algorithms for the scheduling in additive manufacturing

[EN] Genetic Algorithms (GAs) are introduced to tackle the packing problem. The scheduling in Additive Manufacturing (AM) is also dealt with to set up a managed market, called “Lonja3D”. This will enable to determine an alternative tool through the combinatorial auctions, wherein the customers will be able to purchase the products at the best prices from the manufacturers. Moreover, the manufacturers will be able to optimize the production capacity and to decrease the operating costs in each case.This research has been partially financed by the project: “Lonja de Impresión 3D para la Industria 4.0 y la Empresa Digital (LONJA3D)” funded by the Regional Government of Castile and Leon and the European Regional Development Fund (ERDF, FEDER) with grant VA049P17Castillo-Rivera, S.; De Antón, J.; Del Olmo, R.; Pajares, J.; López-Paredes, A. (2020). Genetic algorithms for the scheduling in additive manufacturing. International Journal of Production Management and Engineering. 8(2):59-63. https://doi.org/10.4995/ijpme.2020.12173OJS596382Ahsan, A., Habib, A., Khoda, B. (2015). Resource based process planning for additive manufacturing. Computer-Aided Design, 69, 112-125. https://doi.org/10.1016/j.cad.2015.03.006Araújo, L., Özcan, E., Atkin, J., Baumers, M., Tuck, C., Hague, R. (2015). Toward better build volume packing in additive manufacturing: classification of existing problems and benchmarks. 26th Annual International Solid Freeform Fabrication Symposium - an Additive Manufacturing Conference, 401-410.Berman, B. (2012). 3-D printing: The new industrial revolution. Business Horizons, 55: 155-162. https://doi.org/10.1016/j.bushor.2011.11.003Canellidis, V., Dedoussis, V., Mantzouratos, N., Sofianopoulou, S. (2006). Preprocessing methodology for optimizing stereolithography apparatus build performance. Computers in Industry, 57, 424-436. https://doi.org/10.1016/j.compind.2006.02.004Chergui, A., Hadj-Hamoub, K., Vignata, F. (2018). Production scheduling and nesting in additive manufacturing. Computers & Industrial Engineering, 126, 292-301. https://doi.org/10.1016/j.cie.2018.09.048Demirel, E., Özelkan, E.C., Lim, C. (2018). Aggregate planning with flexibility requirements profile. International Journal of Production Economics, 202, 45-58. https://doi.org/10.1016/j.ijpe.2018.05.001Fera, M., Fruggiero, F., Lambiase, A., Macchiaroli, R., Todisco, V. (2018). A modified genetic algorithm for time and cost optimization of an additive manufacturing single-machine scheduling. International Journal of Industrial Engineering Computations, 9, 423-438. https://doi.org/10.5267/j.ijiec.2018.1.001Hopper, E., Turton, B. (1997). Application of genetic algorithms to packing problems - A Review. Proceedings of the 2nd Online World Conference on Soft Computing in Engineering Design and Manufacturing, Springer Verlag, London, 279-288. https://doi.org/10.1007/978-1-4471-0427-8_30Ikonen, I., Biles, W.E., Kumar, A., Wissel, J.C., Ragade, R.K. (1997). A genetic algorithm for packing three-dimensional non-convex objects having cavities and holes. ICGA, 591-598.Kim, K.H., Egbelu, P.J. (1999). Scheduling in a production environment with multiple process plans per job. International Journal of Production Research, 37, 2725-2753. https://doi.org/10.1080/002075499190491Lawrynowicz, A. (2011). Genetic algorithms for solving scheduling problems in manufacturing systems. Foundations of Management, 3(2), 7-26. https://doi.org/10.2478/v10238-012-0039-2Li, Q., Kucukkoc, I., Zhang, D. (2017). Production planning in additive manufacturing and 3D printing. Computers and Operations Research, 83, 157-172. https://doi.org/10.1016/j.cor.2017.01.013Milošević, M., Lukić, D., Đurđev, M., Vukman, J., Antić, A. (2016). Genetic Algorithms in Integrated Process Planning and Scheduling-A State of The Art Review. Proceedings in Manufacturing Systems, 11(2), 83-88.Pour, M.A., Zanardini, M., Bacchetti, A., Zanoni, S. (2016). Additive manufacturing impacts on productions and logistics systems. IFAC, 49(12), 1679-1684. https://doi.org/10.1016/j.ifacol.2016.07.822Wilhelm, W.E., Shin, H.M. (1985). Effectiveness of Alternate Operations in a Flexible Manufacturing System. International Journal of Production Research, 23(1), 65-79. https://doi.org/10.1080/00207548508904691Xirouchakis, P., Kiritsis, D., Persson, J.G. (1998). A Petri net Technique for Process Planning Cost Estimation. Annals of the CIRP, 47(1), 427-430. https://doi.org/10.1016/S0007-8506(07)62867-4Zhang, Y., Bernard, A., Gupta, R.K., Harik, R. (2014). Evaluating the design for additive manufacturing: a process planning perspective. Procedia CIRP, 21, 144-150. https://doi.org/10.1016/j.procir.2014.03.17

From 3D Models to 3D Prints: an Overview of the Processing Pipeline

Due to the wide diffusion of 3D printing technologies, geometric algorithms for Additive Manufacturing are being invented at an impressive speed. Each single step, in particular along the Process Planning pipeline, can now count on dozens of methods that prepare the 3D model for fabrication, while analysing and optimizing geometry and machine instructions for various objectives. This report provides a classification of this huge state of the art, and elicits the relation between each single algorithm and a list of desirable objectives during Process Planning. The objectives themselves are listed and discussed, along with possible needs for tradeoffs. Additive Manufacturing technologies are broadly categorized to explicitly relate classes of devices and supported features. Finally, this report offers an analysis of the state of the art while discussing open and challenging problems from both an academic and an industrial perspective.Comment: European Union (EU); Horizon 2020; H2020-FoF-2015; RIA - Research and Innovation action; Grant agreement N. 68044

Analysis of irregular three-dimensional packing problems in additive manufacturing: a new taxonomy and dataset

© 2018 Informa UK Limited, trading as Taylor & Francis Group. With most Additive Manufacturing (AM) technology variants, build processes take place inside an internal enclosed build container, referred to as a ‘build volume’. It has been demonstrated that the effectiveness with which this volume is filled with product geometries forms an important determinant of overall process efficiency in AM. For effective operations management, it is important to understand not only the problem faced, but also which methods have proved effective (or ineffective) for problems with these characteristics in the past. This research aims to facilitate this increased understanding. The build volume packing task can be formulated as a three-dimensional irregular packing (3DIP) problem, which is a combinatorial optimisation problem requiring the configuration of a set of arbitrary volumetric items. This paper reviews existing general cutting and packing taxonomies and provides a new specification which is more appropriate for classifying the problems encountered in AM. This comprises a clear-cut problem definition, a set of precise categorisation criteria for objectives and problem instances, and a simple notation. Furthermore, the paper establishes an improved terminology with terms that are familiar to, but not limited to, researchers and practitioners in the field of AM. Finally, this paper describes a new dataset to be used in the evaluation of existing and proposed computational solution methods for 3DIP problems encountered in AM and discusses the importance of this research for further underpinning work

Optimal System Design with Geometric Considerations.

System design is tied to both functionality and geometric realization. The former is pertinent to system performance, and the latter is related to packaging. Packaging is an optimization process that finds a desirable placement for the system components within a given space. When the components do not fit into the allocated space at the packaging stage, the design engineers must make modifications that can affect the performance of the system. The modification of a component can also affect the geometry and positions of other components in the system. These changes might lead to an infeasible layout. Therefore, optimizing the system performance considering packaging is desirable. Packaging problems and solution methods have been studied in many applications, such as electrical circuit layout, glass or metal cutting, truck loading, trunk packing, rapid prototyping (RP), architectural floor plan layout, routing, and mechanical component layout. Packaging problems in a mechanical system design are more challenging than 2D applications such as circuit layout and the metal cutting problem; this is due to a larger design space and increased complexity of geometry. Complex 3D geometry leads to increased computational time for interference checking, which is inevitable for finding a feasible layout. Detailed 3D CAD models, however, are not required or not available at the preliminary design stage. Therefore, abstract representation of the components is necessary during the layout process. Abstract models should balance accuracy of geometry representation and rapid computation capturing designers’ intent. This dissertation presents a computational environment for addressing the combined packaging and optimal system design. The packaging problem also includes pipe generation because pipe routing is also important problems in mechanical system design. The simulation model of a thermal management system for heavy duty series hybrid electric vehicles is used to demonstrate the usefulness of the proposed framework.PHDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttp://deepblue.lib.umich.edu/bitstream/2027.42/108865/1/kwangjae_1.pd

Shortest Geometric Paths Analysis in Structural Biology

The surface of a macromolecule, such as a protein, represents the contact point of any interaction that molecule has with solvent, ions, small molecules or other macromolecules. Analyzing the surface of macromolecules has a rich history but analyzing the distances from this surface to other surfaces or volumes has not been extensively explored. Many important questions can be answered quantitatively through these analyses. These include: what is the depth of a pocket or groove on the surface? what is the overall depth of the protein? how deeply are atoms buried from the surface? where are the tunnels in a protein? where are the pockets and what are their shapes? A single algorithm to solve one graph problem, namely Dijkstra’s shortest paths algorithm, forms the basis for algorithms to answer these many questions. Many distances can be measured, for instance the distance from the convex hull to the molecular surface while avoiding the interior of the surface is defined as Travel Depth. Alternatively, the distance from the surface to every atom can be measured, giving a measure of the Burial Depth of given residues. Measuring the minimum distance to the protein surface for all points in solvent, combined with topological guidance, allows tunnels to be located. Analyzing the surface from the deepest Travel Depth upwards allows pockets to be catalogued over the entire protein surface for additional shape analysis. Ligand binding sites in proteins are significantly deep, though this does not affect the binding affinity. Hyperthermostable proteins have a less deep surface but bury atoms more deeply, forming more spherical shapes than their mesophilic counterparts. Tunnels through proteins can be identified, for the first time tunnels that are winding or bifurcated can be analyzed. Pockets can be found all over the protein surface and these pockets can be tracked through time series, mutational series, or over protein families. All of these results are new and for the first time provide quantitative and statistical verification of some previous hypotheses about protein shape