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Unger, Nicolas and Kamble, Pradnil and Huse, Timo (2025) Novel Slicing Algorithm for Hybrid Manufacturing on Non-Planar Surfaces with Robotic SEAM. In: Advances in Automotive Production Technology – Digital Product Development and Manufacturing, Stuttgart Conference on Automotive Production (SCAP2024), pp. 39-57. Springer Cham. Stuttgart Conference on Automotive Production 2024, 2024-11-20 - 2024-11-22, Stuttgart, Deutschland. doi: 10.1007/978-3-031-88831-1. ISBN 978-3-031-88830-4. ISSN 2524-7247.
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Official URL: https://link.springer.com/book/10.1007/978-3-031-88831-1
Abstract
Combining conventional with additive manufacturing processes opens up new possibilities for the flexible, economical production of complex automotive components and structures with varying geometries. This hybrid manufacturing approach can be realized by 3D-Printing functional structures onto pre-existing parts and surfaces with Robotic Screw Extrusion Additive Manufacturing (RSEAM). The RSEAM process combines the dexterity of industrial robotic arms with the productivity and extensive material range of a screw extruder to provide a highly flexible additive manufacturing process. This paper addresses a critical challenge in hybrid manufacturing: creating suitable manufacturing programs for printing on irregular, non-planar surfaces, that deviate significantly from ideal CAD input. Deviations are classified as macro or micro based on their magnitude relative to the desired printing layer height threshold. We propose a slicing and path-planning algorithm that adapts ideal paths to scanned surfaces and generates optimized trajectories to handle both macro and micro deviations via distinct methods. Macro deviations are handled by offsetting the scanned surface to create layers, smoothing to remove micro deviations and morphing each layer from the ideal CAD onto them. Micro deviations are then accounted for in the first layer by calculating the local non-uniform layer height and locally adjusting the robot velocity. The resulting smooth robot trajectories ensure accurate local bead geometry and correct overall part geometry adaptation. The algorithm's output is validated and optimized within a digital twin of the manufacturing system to avoid collisions and singularities. The implemented algorithms are validated and demonstrated on a real-world automotive application.
| Item URL in elib: | https://elib.dlr.de/207419/ | ||||||||||||||||
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| Document Type: | Conference or Workshop Item (Speech, Other) | ||||||||||||||||
| Title: | Novel Slicing Algorithm for Hybrid Manufacturing on Non-Planar Surfaces with Robotic SEAM | ||||||||||||||||
| Authors: |
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| Date: | 20 June 2025 | ||||||||||||||||
| Journal or Publication Title: | Advances in Automotive Production Technology – Digital Product Development and Manufacturing, Stuttgart Conference on Automotive Production (SCAP2024) | ||||||||||||||||
| Refereed publication: | Yes | ||||||||||||||||
| Open Access: | No | ||||||||||||||||
| Gold Open Access: | No | ||||||||||||||||
| In SCOPUS: | No | ||||||||||||||||
| In ISI Web of Science: | No | ||||||||||||||||
| DOI: | 10.1007/978-3-031-88831-1 | ||||||||||||||||
| Page Range: | pp. 39-57 | ||||||||||||||||
| Editors: |
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| Publisher: | Springer Cham | ||||||||||||||||
| Series Name: | ARENA2036 | ||||||||||||||||
| ISSN: | 2524-7247 | ||||||||||||||||
| ISBN: | 978-3-031-88830-4 | ||||||||||||||||
| Status: | Published | ||||||||||||||||
| Keywords: | Robotic Screw Extrusion Additive Manufacturing Non-Planar Additive Manufacturing Hybrid Part Manufacturing Adaptive Slicing Algorithm Non-Planar Slicing Algorithm Robotic Trajectory Planning 3D Scanning Digital Twin Simulation Automotive Rhino Grasshopper | ||||||||||||||||
| Event Title: | Stuttgart Conference on Automotive Production 2024 | ||||||||||||||||
| Event Location: | Stuttgart, Deutschland | ||||||||||||||||
| Event Type: | international Conference | ||||||||||||||||
| Event Start Date: | 20 November 2024 | ||||||||||||||||
| Event End Date: | 22 November 2024 | ||||||||||||||||
| Organizer: | ARENA2036 e.V. | ||||||||||||||||
| HGF - Research field: | Aeronautics, Space and Transport | ||||||||||||||||
| HGF - Program: | Transport | ||||||||||||||||
| HGF - Program Themes: | Road Transport | ||||||||||||||||
| DLR - Research area: | Transport | ||||||||||||||||
| DLR - Program: | V ST Straßenverkehr | ||||||||||||||||
| DLR - Research theme (Project): | V - FFAE - Fahrzeugkonzepte, Fahrzeugstruktur, Antriebsstrang und Energiemanagement, R - Synergy project Factory of the Future Extended | ||||||||||||||||
| Location: | Stuttgart | ||||||||||||||||
| Institutes and Institutions: | Institute of Vehicle Concepts > Vehicle Architectures and Lightweight Design Concepts | ||||||||||||||||
| Deposited By: | Unger, Nicolas | ||||||||||||||||
| Deposited On: | 01 Jul 2025 13:11 | ||||||||||||||||
| Last Modified: | 01 Jul 2025 13:11 |
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