32 - Optimizing Velocity and Accuracy in Robotic 3D Printing: Impact of Point Density and Interpolation Methods

Abstract

Robotic arms have gained significant popularity in additive manufacturing operations due to their cost-effectiveness and high flexibility. These operations involve the creation of complex shapes by adding material using an end effector and its Tool Center Point (TCP) onto a substrate, following a defined tool path generated by a Computer Assisted Manufacturing (CAM) system. Conventionally, CAM systems generate tool paths using interpolation methods such as linear, circular, or spline interpolation, which allow for accurate manufacturing of complex components. However, linearly interpolated tool paths present inherent discontinuity in velocity and acceleration. To accurately represent complex curves with minimal chord error, a higher number of smaller individual segments is required. This approach leads to a higher point density and a greater total number of points that define the tool path. Nevertheless, if the number of point computations exceeds the processing capabilities of the robot controller, a backlog of computations can occur. This backlog results in delays during trajectory planning and execution, ultimately slowing down the overall motion of the TCP. As a compensation mechanism to maintain path accuracy, the TCP's velocity may decrease. Velocity reductions during additive manufacturing operations can result in printing defects due to material over-deposition, as the deposition rate remains constant. This study aims to explore and quantify the impact of various point densities, interpolation methods, and parameters on the TCP's velocity during additive manufacturing operations. An experimental study is conducted using a six degree-of-freedom (DOF) robotic arm (KR 10 R900-2, by KUKA), where point density, interpolation methods, and parameters of tool paths are systematically generated, varied and acquired using a using a CAM system and its Digital Twin (DT) feature (AdaOne by ADAXIS). The objective is to identify the optimal combination of these factors to achieve a more constant TCP velocity. Drawing upon both industrial and academic sources, the study aims to contribute to the facilitation of more stable additive manufacturing operations.

Speaker

Sami Fadil

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ADAXIS, Bayonne, France

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Conference

32 - Optimizing Velocity and Accuracy in Robotic 3D Printing: Impact of Point Density and Interpolation Methods

Date/Time

20/03/2024

4:40 pm -5:00 pm

Location

Room 8