A virtual prototyping system with reconfigurable actuators for multi-material layered manufacturing

Proliferation of layered manufacturing (LM) in various sectors has been calling for fabrication of large, complex products with more materials and efficiency. We address this issue by integrating reconfigurable manufacturing (RM) with LM. This paper first analyses the benefits of such integration, and then presents a virtual prototyping system with reconfigurable actuators (VPRA) that can increase the number of materials, speed, and build volume to improve the efficiency and flexibility of multi-material layered manufacturing (MMLM). The VPRA system offers a test bed for design, visualization, and validation of MMLM facilities and processes. It takes advantage of the convenient graphics platform of SolidWorks™ for constructing a virtual MMLM facility by selecting reconfigurable actuators from predefined templates. The characteristics, including the dimensions and relative spatial constraints, of the actuators can be conveniently configured to suit design requirements. The mechanism and the operation process of the resulting MMLM facility can then be simulated and validated through digital fabrication of complex objects. Case studies are presented to demonstrate some possible applications of the VPRA system. Overall, the VPRA system gives insights into the characteristics of a reconfigurable MMLM system, which can be subsequently materialized for physical fabrication of multi-material objects. This approach highlights a possible direction for development of MMLM technology.     

Complex concrete structures: Merging existing casting techniques with digital fabrication

Over the course of the 20th century, architectural construction has gone through intense innovation in its material, engineering and design, radically transforming the way buildings were and are conceived. Technological and industrial advances enabled and challenged architects, engineers and constructors to build increasingly complex architectural structures from concrete. Computer-aided design and manufacturing (CAD/CAM) techniques have, more recently, rejuvenated and increased the possibilities of realizing ever more complex geometries. Reinforced concrete is often chosen for such structures as almost any shape can be achieved when placed into a formwork. However, most complex forms generated with these digital design tools bear little relation to the default modes of production used in concrete construction today. A large gap has emerged between the possibilities offered by the digital technology in architectural design and the reality of the building industry, where actually no efficient solutions exist for the production of complex concrete structures. This paper presents construction methods that unfold their full potential by linking digital design, additive fabrication and material properties and hence allow accommodating the construction of complex concrete structures. The emphasis is set on the on-going research project Smart Dynamic Casting (SDC) where advanced material design and robotic fabrication are interconnected in the design and fabrication process of complex concrete structures. The proposed fabrication process is belonging to an emerging architectural phenomenon defined first as Digital Materiality by Gramazio & Kohler (2008) or more recently as Material Ecologies by Neri Oxman  [1].     

Recursive symmetries for geometrically complex and materially heterogeneous additive manufacturing

We present a generative method for the creation of geometrically complex and materially heterogeneous objects. By combining generative design and additive manufacturing, we demonstrate a unique form-finding approach and method for multi-material 3D printing. The method offers a fast, automated and controllable way to explore an expressive set of symmetrical, complex and colored objects, which makes it a useful tool for design exploration and prototyping. We describe a recursive grammar for the generation of solid boundary surface models suitable for a variety of design domains. We demonstrate the generation and digital fabrication of watertight 2-manifold polygonal meshes, with feature-aligned topology that can be produced on a wide variety of 3D printers, as well as post-processed with traditional 3D modeling tools. To date, objects with intricate spatial patterns and complex heterogeneous material compositions generated by this method can only be produced through 3D printing.     

Bidirectional Evolutionary Structural Optimization (BESO) based design method for lattice structure to be fabricated by additive manufacturing

Unlike traditional manufacturing methods, additive manufacturing can produce parts with complex geometric structures without significant increases in fabrication time and cost. One application of additive manufacturing technologies is the fabrication of customized lattice-skin structures which can enhance performance of products while minimizing material or weight. In this paper, a novel design method for the creation of periodic lattice structures is proposed. In this method, Functional Volumes (FVs) and Functional Surfaces (FSs) are first determined based on an analysis of the functional requirements. FVs can be further decomposed into several sub-FVs. These sub-FVs can be divided into two types: FV with solid and FV with lattice. The initial design parameters of the lattice are selected based on the proposed guidelines. Based on these parameters, a kernel based lattice frame generation algorithm is used to generate lattice wireframes within the given FVs. At last, traditional bidirectional evolutionary structural optimization is modified to optimize distribution of lattice struts’ thickness. The design method proposed in this paper is validated through a case study, and provides an important foundation for the wide adoption of additive manufacturing technologies in the industry.     

Data-driven generative design for mass customization: A case study

Generative design provides a promising algorithmic solution for mass customization of products, improving both product variety and design efficiency. However, the current designer-driven generative design formulates the automated program in a manual manner and has insufficient ability to satisfy the diverse needs of individuals. In this work, we propose a data-driven generative design framework by integrating multiple types of data to improve the automation level and performance of detail design to boost design efficiency and improve user satisfaction. A computational workflow including automated shape synthesis and structure design methods is established. More specifically, existing designs selected based on user preferences are utilized in the shape synthesis for creating generative models. For structural design, user-product interaction data gathered by sensors are used as inputs for controlling the spatial distributions of heterogeneous lattice structures. Finally, the proposed concept and workflow are demonstrated with a bike saddle design with a personalized shape and inner structures to be manufactured with additive manufacturing.     

Developing distributed applications for integrated product and process design

A heterogeneous computing environment characterizes today's manufacturing situation. This is a stumbling block for the efficient implementation of manufacturing concepts such as integrated product and process design (IPPD). A computing environment for IPPD would require the seamless integration of the various product and process design software systems. The exchange of information between these systems should be efficient, compatible and synchronous. This article presents an approach for developing distributed manufacturing applications that are compatible and synchronized and thus, able to support IPPD. The approach involves the use of a common manufacturing application ‘middleware’, which is distributed between a central geometric modelling server and application clients. The portability of the middleware is ensured through the use of Java for code portability and XML for data portability. The compatible product model problem is solved through the use of common data structures developed using reusable application client classes. Efficient transfer of product data is proposed using compressed model information embedded in a product data XML schema. Synchronization of design changes among all applications is achieved through the creation of relationships on an Application Relationship Manager.     

A B-spline based framework for volumetric object modeling

With the recent development of Iso-geometric Analysis (IGA) (Cottrell et al., 2009) and advanced manufacturing technologies employing heterogeneous materials, such as additive manufacturing (AM) of functionally graded material, there is a growing emerging need for a full volumetric representation of 3D objects, that prescribes the interior of the object in addition to its boundaries. In this paper, we propose a volumetric representation (V-rep) for geometric modeling that is based on trimmed B-spline trivariates and introduce its supporting volumetric modeling framework. The framework includes various volumetric model (V-model) construction methods from basic non-singular volumetric primitives to high level constructors, as well as Boolean operations’ support for V-models. A V-model is decomposed into and defined by a complex of volumetric cells (V-cells), each of which can also represent a variety of additional varying fields over it, and hence over the entire V-model. With these capabilities, the proposed framework is able of supporting volumetric IGA needs as well as represent and manage heterogeneous materials for AM. Further, this framework is also a seamless extension to existing boundary representations (B-reps) common in all contemporary geometric modeling systems, and allows a simple migration of existing B-rep data, tools and algorithms. Examples of volumetric models constructed using the proposed framework are presented.     

A simulation model for the fabrication of components made from multiphase perfect materials

A component, which has an optimized combination of different materials (including homogeneous materials and different types of heterogeneous materials) in its different portions for a specific application, is considered as the component made of a multiphase perfect material. To manufacture such components, a hybrid layered manufacturing technology was proposed. Since it would be risky and very expensive to make such a physical machine without further study and optimization, manufacturing simulation is adopted to do further research so as to provide the reliable foundation for future practical manufacturing. This paper describes its virtual manufacturing technologies and modeling of the component virtually manufactured. Such a model can be used to evaluate the errors of the virtual manufacturing. Finally, an example of simulating manufacturing process and generating the model of the component virtually manufactured is introduced in more detail.     

A level-set based variational method for design and optimization of heterogeneous objects

A heterogeneous object is referred to as a solid object made of different constituent materials. The object is of a finite collection of regions of a set of prescribed material classes of continuously varying material properties. These properties have a discontinuous change across the interface of the material regions. In this paper, we propose a level-set based variational approach for the design of this class of heterogeneous objects. Central to the approach is a variational framework for a well-posed formulation of the design problem. In particular, we adapt the Mumford-Shah model which specifies that any point of the object belongs to either of two types: inside a material region of a well-defined gradient or on the boundary edges and surfaces of discontinuities. Furthermore, the set of discontinuities is represented implicitly, using a multi-phase level set model. This level-set based variational approach yields a computational system of coupled geometric evolution and diffusion partial differential equations. Promising features of the proposed method include strong regularity in the problem formulation and inherent capabilities of geometric and material modeling, yielding a common framework for optimization of the heterogeneous objects that incorporates dimension, shape, topology, and material properties. The proposed method is illustrated with several 2D examples of optimal design of multi-material structures and materials.     

A multi-material virtual prototyping system

This paper proposes a multi-material virtual prototyping system for digital fabrication of heterogeneous prototypes. It consists mainly of a topological hierarchy-sorting algorithm for processing slice contours, and a virtual simulation system for visualisation and optimisation of multi-material layered manufacturing (MMLM) processes. The topological hierarchy-sorting algorithm processes the hierarchy relationship of complex slice contours. It builds a parent-and-child list that defines the containment relationship of the slice contours, and subsequently arranges the contours in an appropriate sequence, which facilitates toolpath planning for MMLM by avoiding redundant tool movements. The virtual simulation system simulates MMLM processes and provides stereoscopic visualisation of the resulting multi-material prototypes for quality analysis and optimisation of the processes.     

数字制造环境下的加工过程仿真验证技术研究

生产线数字制造环境是数字化工厂的核心，而加工过程的仿真与验证技术构成生产线数字系统的底层结构与制造过程数字化分析的主要内容。分析了目前加工过程在几何仿真与物理仿真方面的研究情况、研究方法与存在问题，就该项技术向生产线数字制造环境融合的关键技术，即综合设备数字样机的完整数字加工环境的建立及加工过程仿真与上层制造环境的信息集成等进行分析与研究。     

A virtual manufacturing system for components made of a multiphase perfect material

A component, which has an optimized combination of different materials (including homogeneous materials and different types of heterogeneous materials) in its different portions for a specific application, is considered as being made of a multiphase perfect material. To manufacture such components, a hybrid layered manufacturing technology has been proposed. Since it would be risky and expensive to make such a physical machine, virtual manufacturing technology is adopted to further study and optimize the hybrid layered manufacturing technology, so as to provide a reliable foundation for future practical manufacturing with a much better prospect of success, a shorter lead time, and a much lower investment cost. This paper develops a virtual manufacturing system for it.     

Using augmented reality to build digital twin for reconfigurable additive manufacturing system

The extrusion-based additive manufacturing (AM) processes are those where one or multiple tools (usually nozzles) are driven along predefined paths to deposit fabrication materials. They are usually inherently slow because solid contours have to be filled with mere single deposition lines of material. An intuitive way to improve the fabrication speed is to introduce multiple independent actuators for concurrent deposition of materials without collision among them. In this paper, a methodology of using augmented reality (AR) technique is presented to conveniently communicate the layout information between a reconfigurable AM system made of robotic arms and its corresponding digital twin for toolpath planning and simulation. A prototype system made of two desktops AM robotic arms is developed, and transformation matrices are derived to determine the spatial relation between different items in the system, including camera, markers, robotic arms and part substrate. Case studies are conducted to demonstrate the capability of this methodology in automatically retrieving layout information and assisting users to deploy pre-determined layout. The results show that the developed methodology enables rapid retrieval of position information from the physical system layout into the digital twin simulation and optimization and facilitates convenient deployment of an optimized layout determined in the digital twin into the physical system.     

A dynamic priority-based approach to concurrent toolpath planning for multi-material layered manufacturing

This paper presents an approach to concurrent toolpath planning for multi-material layered manufacturing (MMLM) to improve the fabrication efficiency of relatively complex prototypes. The approach is based on decoupled motion planning for multiple moving objects, in which the toolpaths of a set of tools are independently planned and then coordinated to deposit materials concurrently. Relative tool positions are monitored and potential tool collisions detected at a predefined rate. When a potential collision between a pair of tools is detected, a dynamic priority scheme is applied to assign motion priorities of tools. The traverse speeds of tools along the x-axis are compared, and a higher priority is assigned to the tool at a higher traverse speed. A tool with a higher priority continues to deposit material along its original path, while the one with a lower priority gives way by pausing at a suitable point until the potential collision is eliminated. Moreover, the deposition speeds of tools can be adjusted to suit different material properties and fabrication requirements. The proposed approach has been incorporated in a multi-material virtual prototyping (MMVP) system. Digital fabrication of prototypes shows that it can substantially shorten the fabrication time of relatively complex multi-material objects. The approach can be adapted for process control of MMLM when appropriate hardware becomes available. It is expected to benefit various applications, such as advanced product manufacturing and biomedical fabrication.     

制造系统中的单向环型设备布局设计

提出一种优化建模与虚拟现实技术相结合的求解策略，较好地解决了制造系统中的单向环型设备布局问题．研究该问题的固有特性，提出三条定理，构建了一个启发式算法，并实现了一个沉浸式虚拟布局设计的例子．     

Computer-aided design of porous artifacts

Heterogeneous structures represent an important new frontier for 21st century engineering. Human tissues, composites, ‘smart’ and multi-material objects are all physically manifest in the world as three-dimensional (3D) objects with varying surface, internal and volumetric properties and geometries. For instance, a tissue engineered structure, such as bone scaffold for guided tissue regeneration, can be described as a heterogeneous structure consisting of 3D extra-cellular matrices (made from biodegradable material) and seeded donor cells and/or growth factors.The design and fabrication of such heterogeneous structures requires new techniques for solid models to represent 3D heterogeneous objects with complex material properties. This paper presents a representation of model density and porosity based on stochastic geometry. While density has been previously studied in the solid modeling literature, porosity is a relatively new problem. Modeling porosity of bio-materials is critical for developing replacement bone tissues. The paper uses this representation to develop an approach to modeling of porous, heterogeneous materials and provides experimental data to validate the approach. The authors believe that their approach introduces ideas from the stochastic geometry literature to a new set of engineering problems. It is hoped that this paper stimulates researchers to find new opportunities that extend these ideas to be more broadly applicable for other computational geometry, graphics and computer-aided design problems.     

Intangibles wear materiality via material composition

The importance of material is gradually increasing in human–computer interfaces (HCIs), especially in the design of physical objects that embody digital information. Because digital information is not comprised of physical material (Belenguer et al., in Proceedings of the Sixth International Conference on Tangible, Embedded and Embodied Interaction, ACM, New York, pp 205–212, 2012) that provides tactile feedback, advancements in HCI research involve combining physical matter with digital representations to embed materiality in immaterial beings. The emergence of new material and transmaterial (Brownell, in transmaterial: a catalog of materials that redefine our physical environment. Princeton Architectural Press, New York, 2005) indicates that material is increasingly becoming a priority in the interaction design field. We emphasize the importance of material in interaction design and discuss categories of material properties according to the characteristics of interactive systems. We divide the pre-existing materials of interaction design into three categories: tangible material, intangible material, and computational material. The relationship between tangible and computational materials has been profoundly discussed since the origin of the tangible user interface. However, intangible materials, such as air, light, and magnetism, are commonly disregarded as distinctive categorical materials in interaction design. In this paper, we argue the effectiveness of intangible materials when they are coupled with tangible and computational mediums and discuss the framework for material composition in interaction design. The concept of material composition suggests the modification of a previous perspective in interaction design, which considers that materials must have either physical or digital properties. The framework of material composition proposes various configuration dimensions that correspond to the quality of the materials used. Therefore, we manifest the framework using Inflated Roly-Poly, which is a previously developed interactive artifact, to determine the success of the reconcilement among the constituent materials and to describe the potential for investigating and resolving further implementation issues.     

Multi-volume CAD modeling for heterogeneous object design and fabrication

The current computer-aided technologies in disign and product development,the evolution of CAD modeling,and a framework of multi-volume CAD modeling system for heterogeneous object design and fabrication are presented in this paper.The multi-volume CAD modeling system is presented based on nonmanifold topological elements.Material identifications are defined as design attributes introduced along with geometric and topological information at the design stage.Extended Euler operation and reasoning Boolean operations for merging and extraction are executed according to the associated material identifications in the developed multi-volume modeling system for heterogeneous object.An application example and a pseudo-processing algorithm for prototyping of heterogeneous structure through solid free-form fabrication are also described.     

Heterogeneous object modeling through direct face neighborhood alteration

Two recent advances—the use of functionally gradient materials in parts and layered manufacturing technology—have brought to the forefront the need for design and fabrication methodologies for heterogeneous objects. However, current solid modeling systems, a core component of computer-aided design and fabrication tools, are typically purely geometry based, and only after the modeling of product geometry, can a part's non-geometric attributes such as material composition be modeled. This sequential order of modeling leads to unnecessary operations and over-segmented 3D regions during heterogeneous object modeling processes.

To enable an efficient design of heterogeneous objects, we propose a novel method, direct face neighborhood operation. This approach combines the geometry and material decisions into a common computational framework as opposed to separate and sequential operations in existing modeling systems. We present theories and algorithms for direction face neighborhood alteration, which enables direct alteration of face neighborhood before 3D regions are formed. This alteration is based on set membership classification (SMC) and region material semantics. The SMC is computationally enhanced by the usage of topological characteristics of heterogeneous objects. After the SMC, boundary evaluation is performed according to the altered face neighborhood. In comparison with other solid modeling methods, the direct face neighborhood alteration method is computationally effective, allows direct B-Rep operations, and is efficient for persistent region naming. A prototype system has been implemented to validate the method and some examples are presented.     

THE OBJECT-ORIENTED INTELLIGENT PROGRAMMING IN CAD/CAM

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