Remanufacturing effectively extends component lifespans by restoring used or end-of-life parts to like-new or even superior conditions, with an emphasis on maximizing reutilized material, especially for high-cost materials. Hybrid manufacturing technology combines the capabilities of additive and subtractive manufacturing, with the ability to add and remove material, enabling it to remanufacture complex shapes and is increasingly being applied in remanufacturing. How to effectively plan the process of additive and subtractive hybrid remanufacturing (ASHRM) to maximize material reutilization has become a key focus of attention. However, current ASHRM process planning methods lack strict consideration of collision-free constraints, hindering practical application. This paper introduces a computational framework to tackle ASHRM process planning for general shapes with strictly considering these constraints. We separate global and local collision-free constraints, employing clipping planes and graph to tackle them respectively, ultimately maximizing the reutilized volume while ensuring these constraints are satisfied. Additionally, we also optimize the setup of the target model that is conducive to maximizing the reutilized volume. Extensive experiments and physical validations on a 5-axis hybrid manufacturing platform demonstrate the effectiveness of our method across various 3D shapes, achieving an average material reutilization of 69% across 12 cases. Code is publicly available at https://github.com/fanchao98/Waste-to-Value.

Additive and subtractive hybrid manufacturing (ASHM) involves the alternating use of additive and subtractive manufacturing techniques, which provides unique advantages for fabricating complex geometries with otherwise inaccessible surfaces. However, a significant challenge lies in ensuring tool accessibility during both fabrication procedures, as the object shape may change dramatically, and different parts of the shape are interdependent. In this study, we propose a computational framework to optimize the planning of additive and subtractive sequences while ensuring tool accessibility. Our goal is to minimize the switching between additive and subtractive processes to achieve efficient fabrication while maintaining product quality. We approach the problem by formulating it as a Volume-And-Surface-CO-decomposition (VASCO) problem. First, we slice volumes into slabs and build a dynamic-directed graph to encode manufacturing constraints, with each node representing a slab and direction reflecting operation order. We introduce a novel geometry property called hybrid-fabricability for a pair of additive and subtractive procedures. Then, we propose a beam-guided top-down block decomposition algorithm to solve the VASCO problem. We apply our solution to a 5-axis hybrid manufacturing platform and evaluate various 3D shapes. Finally, we assess the performance of our approach through both physical and simulated manufacturing evaluations.