Motion and Path Planning for Additive Manufacturing

Alex Roschli obtained a Bachelor's and Master's Degree in Electrical Engineering from the University of Tennessee in 2015 and 2016, respectively. He has conducted research in the Manufacturing Demonstration Facility at Oak Ridge National Laboratory (ORNL) since 2012. His area of expertise and research has centered around the development of large format additive manufacturing and the BAAM (Big Area Additive Manufacturing) system. He has played an integral role in many projects such as 3D printing the first car, a Shelby Cobra, a Guinness World Record holding Boeing 777x wing blade mold, a wind turbine blade mold, and a 34' catamaran boat hull mold. His current focus is software development for toolpath generation in additive manufacturing. This includes slicing, printing, motor and extrusion control, and closed loop data feedback. Alex manages development of ORNL Slicer 2, a novel toolpath generation software produced at ORNL.Dr. Michael Borish is a research staff member in the Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL), having joined in 2017. At the MDF, he engages in a wide range of disciplines within Computer Science as they relate to industrial additive manufacturing. This research encompasses visualization, augmented reality, path planning, and computer vision, to name a few. He hopes to expand the boundaries of what we define as manufacturing technology. He is also interested in altering established paradigms of operation particularly as it relates to slicing and path planning and has been developing custom slicing software to that end. He has also built an open-source community around slicing software to advance the state of the art in path planning for industrial additive manufacturing.Abby Barnes is a Research Communications Professional at Oak Ridge National Laboratory's Manufacturing Demonstration Facility. She was previously a researcher in at the University of Tennessee, Knoxville. She has co-authored two research papers and contributed to five others. Thomas Feldhausen is a research staff member and technical lead for hybrid manufacturing at Oak Ridge National Laboratory's Manufacturing Automation and Controls Group. Hybrid manufacturing, a combination of additive and subtractive (machining) manufacturing, is used in his research at ORNL's Manufacturing Demonstration Facility to provide industrial solutions for component repair, tooling and tooling repair, advanced energy systems, aerospace, and automotive applications. Thomas worked at Honeywell Federal Manufacturing in Kansas City before coming to ORNL, where he specialized in multi-axis additive processes for direct ink-write technology. Peter Wang is a research staff scientist in the Manufacturing Systems Design Group at Oak Ridge National Laboratory (ORNL). Prior to working at ORNL, he worked in aerospace and underground construction industries for 12 years. His previous work experience has covered mechanical and civil structural design, heavy machine design, project management and construction site automation. He obtained his PhD in 2018 from the University of California, Irvine with a focus in robot kinematics. His current research interests cover robotics, manufacturing systems development, automation, additive manufacturing, and the circular economy. Eric MacDonald, Ph.D. is Professor of Aerospace and Mechanical Engineering and Murchison Chair at the University of Texas at El Paso, and serves as the Associate Dean of Research and Graduate Studies for the College of Engineering. Dr. MacDonald received his doctoral degree in Electrical and Computer Engineering from the University of Texas at Austin in 2002. He worked in industry for 12 years at IBM and Motorola and subsequently co-founded a start-up specializing in CAD software, which was subsequently acquired by a firm in Silicon Valley. Dr. MacDonald held faculty fellowships at NASA’s Jet Propulsion Laboratory, US Navy Research and was awarded a US State Department Fulbright Fellowship in South America. His research interests include 3D printed multi-functional applications and process monitoring in additive manufacturing with instrumentation and computer vision for improved quality and yield.

• 1. Introduction to AM2. Kinematics of Motion3. Motion Platforms4. Geometry Data Storage5. Cross-sectioning6. Closed-Loop Toolpath Generation7. Space Filling Toolpath Generation8. Open-Loop Toolpath Generation9. Support, Raft, Brim, and Skirt Pathing10. Path Modifiers11. Travels, Optimizations, and Ordering12. Pathing Considerations for Extrusion: Pellet, Filament, Concrete and Thermoset13. Pathing Considerations for DED: Arc Welding and Laser Welding14. Planar Slicing for Non-Extrusion AM Processes15. Nonplanar Slicing16. Pathing Considerations for 5-Axis Planar AM17. Pathing Considerations for Hybrid AM18. The G-Code File19. Closing The Loop