Support optimization for additive manufacturing: application to FDM

Purpose This paper aims to present a new methodology to optimize the support generation within the FDM process. Design/methodology/approach Different methods of support generation exist, but they are limited with regards to complex parts. This paper proposes a method dedicated to support generation, integrated into CAD software. The objective is to minimize the volume of support and its impact on a part’s surface finish. Two case studies illustrate the methodology. The support generation is based on an octree’s discretization of the part. Findings The method represents a first solid step in the support optimization for a reasonable calculation time. It has the advantage of being virtually automatic. The only tasks to be performed by the designer are to place the part to be studied with respect to the CAD reference and to give the ratio between the desired support volume and the maximum volume of support. Research limitations/implications In the case studies, a low gain in manufacturing time was observed. This is explained by the honeycomb structure of the support generated by a common slicing software whilst the proposed method uses a “full” structure. It would be interesting to study the feasibility of an optimized support, with a honeycomb structure but with a preservation of the surface which is in contact with the part. Originality/value This solution best fits the needs of the designer and manufacturer already taking advantage of existing solutions. It is adaptable to any part if the withdrawal of support is taken into account. It also allows the designer to validate the generation of support throughout the CAD without breaking the digital chain

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

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 non-planar 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

Optimising mobile laser scanning for underground mines

Despite several technological advancements, underground mines are still largely relied on visual inspections or discretely placed direct-contact measurement sensors for routine monitoring. Such approaches are manual and often yield inconclusive, unreliable and unscalable results besides exposing mine personnel to field hazards. Mobile laser scanning (MLS) promises an automated approach that can generate comprehensive information by accurately capturing large-scale 3D data. Currently, the application of MLS has relatively remained limited in mining due to challenges in the post-registration of scans and the unavailability of suitable processing algorithms to provide a fully automated mapping solution. Additionally, constraints such as the absence of a spatial positioning network and the deficiency of distinguishable features in underground mining spaces pose challenges in mobile mapping. This thesis aims to address these challenges in mine inspections by optimising different aspects of MLS: (1) collection of large-scale registered point cloud scans of underground environments, (2) geological mapping of structural discontinuities, and (3) inspection of structural support features. Firstly, a spatial positioning network was designed using novel three-dimensional unique identifiers (3DUID) tags and a 3D registration workflow (3DReG), to accurately obtain georeferenced and coregistered point cloud scans, enabling multi-temporal mapping. Secondly, two fully automated methods were developed for mapping structural discontinuities from point cloud scans – clustering on local point descriptors (CLPD) and amplitude and phase decomposition (APD). These methods were tested on both surface and underground rock mass for discontinuity characterisation and kinematic analysis of the failure types. The developed algorithms significantly outperformed existing approaches, including the conventional method of compass and tape measurements. Finally, different machine learning approaches were used to automate the recognition of structural support features, i.e. roof bolts from point clouds, in a computationally efficient manner. Roof bolts being mapped from a scanned point cloud provided an insight into their installation pattern, which underpinned the applicability of laser scanning to inspect roof supports rapidly. Overall, the outcomes of this study lead to reduced human involvement in field assessments of underground mines using MLS, demonstrating its potential for routine multi-temporal monitoring