Abstract Simultaneous four‐axis machining involves a cutter that moves in all degrees of freedom during carving. This strategy provides higher‐quality surface finishing compared to positional machining. However, it has not been well‐studied in research. In this study, we propose the first end‐to‐end computational framework to optimize the toolpath for fabricating complex models using simultaneous four‐axis subtractive manufacturing. In our technique, we first slice the input 3D model into uniformly distributed 2D layers. For each slicing layer, we perform an accessibility analysis for each intersected contour within this layer. Then, we proceed with over‐segmentation and a bottom‐up connecting process to generate a minimal number of fabricable segments. Finally, we propose post‐processing techniques to further optimize the tool directionand the transfer path between segments. Physical experiments of nine models demonstrate our significant improvements in both fabrication quality and efficiency, compared to the positional strategy and two simultaneous tool paths generated by industry‐standard CAM systems.

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.

the input target wire with consecutive line segments and circular segments to ensure the bending manufacturing constraints for each segment, then generate tuned wire through a bilevel optimization.This involves selecting the bending points at the upper level with a beam search strategy and determining the specifically tuned angles at the lower level.We perform a thorough physical evaluation using a DIY wire-bending machine.The results show the effectiveness of our proposed approach in realizing a wide range of intricate and complex wire sculptures.

In this study, we propose a computational framework for optimizing the continuity of the toolpath in fabricating surface models on an extrusion-based 3D printer. Toolpath continuity is a critical issue that influences both the quality and the efficiency of extrusion-based fabrication. Transfer moves lead to rough and bumpy surfaces, where this phenomenon worsens for materials with large viscosity, like clay. The effects of continuity on the surface models are even more severe in terms of the quality of the surface and the stability of the model. We introduce a criterion called the one–path patch (OPP) to represent a patch on the surface of the shell that can be traversed along one path by considering the constraints on fabrication. We study the properties of the OPPs and their merging operations to propose a bottom-up OPP merging procedure to decompose the given shell surface into a minimal number of OPPs, and to generate the “as-continuous-as-possible” (ACAP) toolpath. Furthermore, we augment the path planning algorithm with a curved-layer printing scheme that reduces staircase defects and improves the continuity of the toolpath by connecting multiple segments. We evaluated the ACAP algorithm on ceramic and thermoplastic materials, and the results showed that it improves the fabrication of surface models in terms of both efficiency and surface quality.

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.