Process monitoring for material extrusion additive manufacturing: a state-of-the-art review

Qualitative uncertainties are a key challenge for the further industrialization of additive manufacturing. To solve this challenge, methods for measuring the process states and properties of parts during additive manufacturing are essential. The subject of this review is in-situ process monitoring for material extrusion additive manufacturing. The objectives are, first, to quantify the research activity on this topic, second, to analyze the utilized technologies, and finally, to identify research gaps. Various databases were systematically searched for relevant publications and a total of 221 publications were analyzed in detail. The study demonstrated that the research activity in this field has been gaining importance. Numerous sensor technologies and analysis algorithms have been identified. Nonetheless, research gaps exist in topics such as optimized monitoring systems for industrial material extrusion facilities, inspection capabilities for additional quality characteristics, and standardization aspects. This literature review is the first to address process monitoring for material extrusion using a systematic and comprehensive approach

Exploiting gan as an oversampling method for imbalanced data augmentation with application to the fault diagnosis of an industrial robot

O diagnóstico inteligente de falhas baseado em aprendizagem máquina geralmente requer um conjunto de dados balanceados para produzir um desempenho aceitável. No entanto, a obtenção de dados quando o equipamento industrial funciona com falhas é uma tarefa desafiante, resultando frequentemente num desequilíbrio entre dados obtidos em condições nominais e com falhas. As técnicas de aumento de dados são das abordagens mais promissoras para mitigar este problema. Redes adversárias generativas (GAN) são um tipo de modelo generativo que consiste de um módulo gerador e de um discriminador. Por meio de aprendizagem adversária entre estes módulos, o gerador otimizado pode produzir padrões sintéticos que podem ser usados para amumento de dados. Investigamos se asGANpodem ser usadas como uma ferramenta de sobre amostra- -gem para compensar um conjunto de dados desequilibrado em uma tarefa de diagnóstico de falhas num manipulador robótico industrial. Realizaram-se uma série de experiências para validar a viabilidade desta abordagem. A abordagem é comparada com seis cenários, incluindo o método clássico de sobre amostragem SMOTE. Os resultados mostram que a GAN supera todos os cenários comparados. Para mitigar dois problemas reconhecidos no treino das GAN, ou seja, instabilidade de treino e colapso de modo, é proposto o seguinte. Propomos uma generalização da GAN de erro quadrado médio (MSE GAN) da Wasserstein GAN com penalidade de gradiente (WGAN-GP), referida como VGAN (GAN baseado numa matriz V) para mitigar a instabilidade de treino. Além disso, propomos um novo critério para rastrear o modelo mais adequado durante o treino. Experiências com o MNIST e no conjunto de dados do manipulador robótico industrial mostram que o VGAN proposto supera outros modelos competitivos. A rede adversária generativa com consistência de ciclo (CycleGAN) visa lidar com o colapso de modo, uma condição em que o gerador produz pouca ou nenhuma variabilidade. Investigamos a distância fatiada de Wasserstein (SWD) na CycleGAN. O SWD é avaliado tanto no CycleGAN incondicional quanto no CycleGAN condicional com e sem mecanismos de compressão e excitação. Mais uma vez, dois conjuntos de dados são avaliados, ou seja, o MNIST e o conjunto de dados do manipulador robótico industrial. Os resultados mostram que o SWD tem menor custo computacional e supera o CycleGAN convencional.Machine learning based intelligent fault diagnosis often requires a balanced data set for yielding an acceptable performance. However, obtaining faulty data from industrial equipment is challenging, often resulting in an imbalance between data acquired in normal conditions and data acquired in the presence of faults. Data augmentation techniques are among the most promising approaches to mitigate such issue. Generative adversarial networks (GAN) are a type of generative model consisting of a generator module and a discriminator. Through adversarial learning between these modules, the optimised generator can produce synthetic patterns that can be used for data augmentation. We investigate whether GAN can be used as an oversampling tool to compensate for an imbalanced data set in an industrial robot fault diagnosis task. A series of experiments are performed to validate the feasibility of this approach. The approach is compared with six scenarios, including the classical oversampling method (SMOTE). Results show that GAN outperforms all the compared scenarios. To mitigate two recognised issues in GAN training, i.e., instability and mode collapse, the following is proposed. We proposed a generalization of both mean sqaure error (MSE GAN) and Wasserstein GAN with gradient penalty (WGAN-GP), referred to as VGAN (the V-matrix based GAN) to mitigate training instability. Also, a novel criterion is proposed to keep track of the most suitable model during training. Experiments on both the MNIST and the industrial robot data set show that the proposed VGAN outperforms other competitive models. Cycle consistency generative adversarial network (CycleGAN) is aiming at dealing with mode collapse, a condition where the generator yields little to none variability. We investigate the sliced Wasserstein distance (SWD) for CycleGAN. SWD is evaluated in both the unconditional CycleGAN and the conditional CycleGAN with and without squeeze-and-excitation mechanisms. Again, two data sets are evaluated, i.e., the MNIST and the industrial robot data set. Results show that SWD has less computational cost and outperforms conventional CycleGAN

Safe and accurate MAV Control, navigation and manipulation

This work focuses on the problem of precise, aggressive and safe Micro Aerial Vehicle (MAV) navigation as well as deployment in applications which require physical interaction with the environment. To address these issues, we propose three different MAV model based control algorithms that rely on the concept of receding horizon control. As a starting point, we present a computationally cheap algorithm which utilizes an approximate linear model of the system around hover and is thus maximally accurate for slow reference maneuvers. Aiming at overcoming the limitations of the linear model parameterisation, we present an extension to the first controller which relies on the true nonlinear dynamics of the system. This approach, even though computationally more intense, ensures that the control model is always valid and allows tracking of full state aggressive trajectories. The last controller addresses the topic of aerial manipulation in which the versatility of aerial vehicles is combined with the manipulation capabilities of robotic arms. The proposed method relies on the formulation of a hybrid nonlinear MAV-arm model which also takes into account the effects of contact with the environment. Finally, in order to enable safe operation despite the potential loss of an actuator, we propose a supervisory algorithm which estimates the health status of each motor. We further showcase how this can be used in conjunction with the nonlinear controllers described above for fault tolerant MAV flight. While all the developed algorithms are formulated and tested using our specific MAV platforms (consisting of underactuated hexacopters for the free flight experiments, hexacopter-delta arm system for the manipulation experiments), we further discuss how these can be applied to other underactuated/overactuated MAVs and robotic arm platforms. The same applies to the fault tolerant control where we discuss different stabilisation techniques depending on the capabilities of the available hardware. Even though the primary focus of this work is on feedback control, we thoroughly describe the custom hardware platforms used for the experimental evaluation, the state estimation algorithms which provide the basis for control as well as the parameter identification required for the formulation of the various control models. We showcase all the developed algorithms in experimental scenarios designed to highlight the corresponding strengths and weaknesses as well as show that the proposed methods can run in realtime on commercially available hardware.Open Acces

Improving precision of material extrusion 3D printing by in-situ monitoring and predicting 3D geometric deviation using Conditional Adversarial Networks

The field of additive manufacturing, especially 3D printing, has gained growing attention in the research and commercial sectors in recent years. Notwithstanding that the capabilities of 3D printing have moved on to enhanced resolution, higher deposition rate, and a wide variety of materials, the crucial challenge of verifying that the component manufactured is within the dimensional tolerance as designed continues to exist. Material extrusion 3D printing has long been established for rapid prototyping and functional testing in many research and industry fields. However, its inconsistency and intrinsic defects (surface roughness and geometric inaccuracies) hinder its application in several areas, most notably “certify-as-you- build” small-batch prototyping and large-batch production.In this study, we present an approach to reduce both inconsistency and the 3D geometric inaccuracies of products fabricated by material extrusion.1. This work developed and demonstrated an approach for layer-by-layer mapping of 3D printed parts, which can be used for validation of printed models and in situ adjustment of print parameters. This in situ metrology system scans each layer at the time of printing, providing a 3D model of the as-printed part. A high-speed optical scanning system was integrated with a Material Extrusion type 3D printer to achieve in situ monitoring of dimensional inaccuracies during printing, which leaves the door open to implement a closed-loop feedback system to compensate geometric errors during printing in the future and fabricate “certify-as-you-build” products.2. This work trained machine learning algorithms with data from this scanning system and predicted 3D geometric inaccuracies in new designs. Eight Conditional Adversarial Networks (CAN) machine learning models were trained on a limited number of scanned profile images of different layers, consisting of less than 50 actual images and 50 generated images, to predict the 3D geometric deviations of freeform shapes. The generated images were produced by randomly combining and cropping the actual images without any distortion. These CAN models produced predictions where at least 44.4%, 87.6%, 99.2% of data were within �0.05 mm, �0.10 mm, �0.15 mm of the actual measured value, respectively.3. This work developed an Iterative Forward approach to redesign the Computer-Aided- Design model by reverse engineering using the trained machine learning models, allowing for compensation of print imperfection at the design stage, in advance of the first printing. The compensation algorithms with eight different sets of different parameters were evaluated. It has been proven that the Iterative Forward approach improved the geometric deviation of the predicted profiles by making compensation to the CAD model

Optimization of 4D/3D printing via machine learning: a systematic review

This systematic review explores the integration of 4D/3D printing technologies with machine learning, shaping a new era of manufacturing innovation. The analysis covers a wide range of research papers, articles, and patents, presenting a multidimensional perspective on the advancements in additive manufacturing. The review underscores machine learning's pivotal role in optimizing 4D/3D printing, addressing aspects like design customization, material selection, process control, and quality assurance. The examination reveals novel techniques enabling the fabrication of intelligent, self-adaptive structures capable of transformation over time. Additionally, the review investigates the use of predictive algorithms to enhance efficiency, reliability, and sustainability in 4D/3D printing processes. Applications span aerospace, healthcare, architecture, and consumer goods, showcasing the potential to create intricate, personalized, and once-unattainable functional products. The synergy between machine learning and 4D/3D printing is poised to unlock new manufacturing horizons, enabling rapid responses to market demands and sustainability challenges. In summary, this review provides a comprehensive overview of the current state of 4D/3D printing optimization through machine learning, highlighting the transformative potential of this interdisciplinary fusion and offering a roadmap for future research and development. It aims to inspire innovators, researchers, and industries to harness this powerful combination for accelerated evolution in manufacturing processes into the 21st century and beyond

Aviation Safety/Automation Program Conference

The Aviation Safety/Automation Program Conference - 1989 was sponsored by the NASA Langley Research Center on 11 to 12 October 1989. The conference, held at the Sheraton Beach Inn and Conference Center, Virginia Beach, Virginia, was chaired by Samuel A. Morello. The primary objective of the conference was to ensure effective communication and technology transfer by providing a forum for technical interchange of current operational problems and program results to date. The Aviation Safety/Automation Program has as its primary goal to improve the safety of the national airspace system through the development and integration of human-centered automation technologies for aircraft crews and air traffic controllers

Application of advanced technology to space automation

Automated operations in space provide the key to optimized mission design and data acquisition at minimum cost for the future. The results of this study strongly accentuate this statement and should provide further incentive for immediate development of specific automtion technology as defined herein. Essential automation technology requirements were identified for future programs. The study was undertaken to address the future role of automation in the space program, the potential benefits to be derived, and the technology efforts that should be directed toward obtaining these benefits

First Annual Workshop on Space Operations Automation and Robotics (SOAR 87)

Several topics relative to automation and robotics technology are discussed. Automation of checkout, ground support, and logistics; automated software development; man-machine interfaces; neural networks; systems engineering and distributed/parallel processing architectures; and artificial intelligence/expert systems are among the topics covered