Efficient toolpath planning for collaborative material extrusion machines

• Published in: Rapid prototyping journal Vol. 29; no. 9; pp. 1814 - 1828
• Main Authors: Bacciaglia, Antonio, Ceruti, Alessandro
• Format: Journal Article
• Language: English
• Published: Bradford Emerald Group Publishing Limited 18.10.2023
• Subjects: Algorithms; CAD; Collaboration; Collision avoidance; Computer aided design; Design; Extruders; Extrusion; G codes; Inserts; Manufacturing; Methodology; Process planning; Rapid prototyping; Software; Trajectory planning; Unmanned aerial vehicles
• ISSN: 1355-2546; 1758-7670
• DOI: 10.1108/RPJ-09-2022-0320

PurposeTiming constraints affect the manufacturing of traditional large-scale components through the material extrusion technique. Thus, researchers are exploring using many independent and collaborative heads that may work on the same part simultaneously while still producing an appealing final product. The purpose of this paper is to propose a simple and repeatable approach for toolpath planning for gantry-based n independent extrusion heads with effective collision avoidance management.Design/methodology/approachThis research presents an original toolpath planner based on existing slicing software and the traditional structure of G-code files. While the computationally demanding component subdivision task is assigned to computer-aided design and slicing software to build a standard G-code, the proposed algorithm scans the conventional toolpath data file, quickly isolates the instructions of a single extruder and inserts brief pauses between the instructions if the non-priority extruder conflicts with the priority one.FindingsThe methodology is validated on two real-life industrial large-scale components using architectures with two and four extruders. The case studies demonstrate the method's effectiveness, reducing printing time considerably without affecting the part quality. A static priority strategy is implemented, where one extruder gets priority over the other using a cascade process. The results of this paper demonstrate that different priority strategies reflect on the printing efficiency by a factor equal to the number of extrusion heads.Originality/valueTo the best of the authors’ knowledge, this is the first study to produce an original methodology to efficiently plan the extrusion heads' trajectories for a collaborative material extrusion architecture.