Engineering topics

Wang, Peter

Publications and source records attributed to Wang, Peter.

28 records · Page 2

DOE OSTI2023

7. Space-Filling Toolpath Generation

Space-filling toolpaths are used to fill whatever space remains on a layer after closed-loop contours have been planned. They provide structure to the object, both supporting the geometry and creating solid surfaces. As such, there are two main types of space-filling toolpaths: infill and skin. Infill paths are sparse and meant to cover a large area quickly. Infill is typically not visible once a print is complete, because infill is covered by skins. Skins are the solid space-filling toolpaths meant to solidify the top and bottom of the object, which, unlike the sides of the object, are not completely covered by layering contours. Space-filling paths are typically planned by projecting a pattern over the layer, clipping the pattern at the boundary of the object, and then linking the remaining portions of the pattern. A subcategory of skin paths, called gradual infill, can be employed to densify the infill when approaching a top skin layer so that the print path of the top skin is sufficiently supported. Space-filling paths come in a variety of patterns to optimize how the space is filled. This chapter will discuss space-filling path categories, how to find the space for each path type, and how to apply the path type to generate toolpaths.

Roschli, Alex↗

DOE OSTI2023

6. Closed-Loop Toolpath Generation

Closed-loop paths, also known as closed-loop contours, are paths that start and stop at the same point and are typically used to define the perimeter or outermost boundary of the polygon that represents a given layer of an object, referred to as the “layer polygon.” Finding the location of a closed-loop path involves applying two offsetting steps to the edge of the layer polygon. The offsetting steps respectively serve to (1) find the area that contains the toolpath and (2) find the centerline of that area, to define the path itself. After finding the perimeter path, the remaining geometry from the layer polygon can be used for additional path-planning steps. This chapter will discuss how the location for a closed-loop path is found, including various problem scenarios, and the different types of closed-loop paths used in additive manufacturing.

Roschli, Alex↗

DOE OSTI2023

5. Cross-Sectioning

Now that an object has been transformed to an STL representation, the first major step of the slicing process can begin: cross-sectioning. This step converts a 3D object into a stack of polygons. Polygons are closed, 2D shapes composed of straight edges. These polygons are typically the result of intersecting a plane with an object at various heights along the z-axis. These stacked polygons create the “layers” that are characteristic of the 3D-printing process. In addition to the cross-section operation itself, several details need to be addressed. These details include necessary preprocessing and potential stitching, smoothing, and simplification of the cross-sections.

Borish, Michael↗

DOE OSTI2023

4. Geometry Data Storage

3D-printing begins with the design of an object using computer aided design (CAD) software. The geometry of the object must be exported and saved in a data file format that can be used in the slicing process to generate machine instructions for printing. The standard method of saving the data is to tessellate the object as a triangulated mesh stored as a .stl file. Due to the flat triangular faces used to store the data, this mesh is a low-resolution representation of the high-fidelity object designed in CAD. The STL has its limitations with respect to geometrical accuracy, material information, and instances of invalid mesh data, but can still be used for the 3D-printing process. New file variants, such as OBJ, AMF, and 3MF, are being developed to fix some of these issues and increase the capabilities of geometry data storage for 3D-printing.

Roschli, Alex↗

DOE OSTI2023

3. Motion Platforms and Kinematic Arrangements

Within a machine, mechanisms and motion are organized in what is known as a “kinematic arrangement,” which helps classify machines based on how they move. The most common kinematic arrangements for additive manufacturing systems are Cartesian, followed by delta, and then six-degrees-of-freedom robotic arms. However, there are a multitude of less common systems, such as the SCARA, polar robots, cable driven parallel robots, mobile platforms, and multi-agent systems. This chapter surveys these various kinematic arrangements to give a broad understanding of the mechanisms underlying motion within additive manufacturing systems. Understanding these mechanisms and their resulting motion provides a framework for discussing path planning for all scales and families of additive manufacturing.

Wang, Peter↗

DOE OSTI2023

Dynamic Beam Shape Sensing and Control in an Open Architecture Metal AM System for Microstructure Manipulation

Most commercially available metal additive manufacturing (AM) systems are closed-architecture, meaning that the system manufacturer limits the ability of the user to directly control the process conditions and can modify the specified inputs using proprietary methods. Unfortunately, this approach severely limits or confounds the ability for users to perform research on fundamental aspects of additive manufacturing. ARCTOS Technology Solutions (ARCTOS) produces an open-architecture laser powder bed fusion (PBF) additive manufacturing system that allows the user to fully control all aspects of the process control and monitoring. The purpose of this project is to help develop beam shaping capabilities and controls within the ARCTOS open-architecture system for control of microstructure evolution during metal AM.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Development and Evaluation of Sensor Concepts for Ageless Aerospace Vehicles: Report 6 - Development and Demonstration of a Self-Organizing Diagnostic System for Structural Health Monitoring

This report describes a significant advance in the capability of the CSIRO/NASA structural health monitoring Concept Demonstrator (CD). The main thrust of the work has been the development of a mobile robotic agent, and the hardware and software modifications and developments required to enable the demonstrator to operate as a single, self-organizing, multi-agent system. This single-robot system is seen as the forerunner of a system in which larger numbers of small robots perform inspection and repair tasks cooperatively, by self-organization. While the goal of demonstrating self-organized damage diagnosis was not fully achieved in the time available, much of the work required for the final element that enables the robot to point the video camera and transmit an image has been completed. A demonstration video of the CD and robotic systems operating will be made and forwarded to NASA.

Batten, Adam↗

NASA NTRS2009

Development and Evaluation of Sensor Concepts for Ageless Aerospace Vehicles: Report 5 - Phase 2 Implementation of the Concept Demonstrator

This report describes the second phase of the implementation of the Concept Demonstrator experimental test-bed system containing sensors and processing hardware distributed throughout the structure, which uses multi-agent algorithms to characterize impacts and determine a suitable response to these impacts. This report expands and adds to the report of the first phase implementation. The current status of the system hardware is that all 192 physical cells (32 on each of the 6 hexagonal prism faces) have been constructed, although only four of these presently contain data-acquisition sub-modules to allow them to acquire sensor data. Impact detection.. location and severity have been successfully demonstrated. The software modules for simulating cells and controlling the test-bed are fully operational. although additional functionality will be added over time. The visualization workstation displays additional diagnostic information about the array of cells (both real and simulated) and additional damage information. Local agent algorithms have been developed that demonstrate emergent behavior of the complex multi-agent system, through the formation of impact damage boundaries and impact networks. The system has been shown to operate well for multiple impacts. and to demonstrate robust reconfiguration in the presence of damage to numbers of cells.

Batten, Adam↗

NASA NTRS2008

Development and Evaluation of Sensor Concepts for Ageless Aerospace Vehicles: Report 4 - Phase 1 Implementation of the Concept Demonstrator

This report describes the first phase of the implementation of the Concept Demonstrator. The Concept Demonstrator system is a powerful and flexible experimental test-bed platform for developing sensors, communications systems, and multi-agent based algorithms for an intelligent vehicle health monitoring system for deployment in aerospace vehicles. The Concept Demonstrator contains sensors and processing hardware distributed throughout the structure, and uses multi-agent algorithms to characterize impacts and determine an appropriate response to these impacts.

Abbott, David↗

NASA NTRS2008

Development and Evaluation of Sensor Concepts for Ageless Aerospace Vehicles: Report 3 - Design of the Concept Demonstrator

This report provides an outline of the essential features of a Structural Health Monitoring Concept Demonstrator (CD) that will be constructed during the next eight months. It is emphasized that the design cannot be considered to be complete, and that design work will continue in parallel with construction and testing. A major advantage of the modular design is that small modules of the system can be developed, tested and modified before a commitment is made to full system development. The CD is expected to develop and evolve for a number of years after its initial construction. This first stage will, of necessity, be relatively simple and have limited capabilities. Later developments will improve all aspects of the functionality of the system, including sensing, processing, communications, intelligence and response. The report indicates the directions this later development will take.

Abbott, David↗