We propose a method for integrated tool path planning and support structure generation tailored to the specific constraints of extrusion-based ceramics printing. Existing path generation methods for thermoplastic materials rely on transfer moves to navigate between different print paths in a given layer. However, when printing with clay, these transfer moves can lead to severe artifacts and failure. Our method eliminates transfer moves altogether by generating deposition paths that are continuous within and across layers. Our algorithm is implemented as a sequential top-down pass through the layer stack. In each layer, we detect points that require support, connect support points and model paths, and optimize the shape of the resulting continuous path with respect to length, smoothness, and distance to the model. For each of these subproblems, we propose dedicated solutions that take into account the fabrication constraints imposed by printable clay. We evaluate our method on a set of examples with multiple disconnected components and challenging support requirements. Comparisons to existing path generation methods designed for thermoplastic materials show that our method substantially improves print quality and often makes the difference between success and failure.

In traditional design, shapes are first conceived, and then fabricated. While this decoupling simplifies the design process, it can result in unwanted material wastage, especially where off-cut pieces are hard to reuse. In absence of explicit feedback on material usage, the designer remains helpless to effectively adapt the design - even when design variabilities exist. We investigate waste minimizing furniture design wherein based on the current design, the user is presented with design variations that result in less wastage of materials. Technically, we dynamically analyze material space layout to determine which parts to change and how , while maintaining original design intent specified in the form of design constraints. We evaluate the approach on various design scenarios, and demonstrate effective material usage that is difficult, if not impossible, to achieve without computational support.

Abstract The success of physics sandbox applications and physics‐based puzzle games is a strong indication that casual users and hobbyists enjoy designing mechanisms, for educational or entertainment purposes. In these applications, a variety of mechanisms are designed by assembling two‐dimensional shapes, creating gears, cranks, cams, and racks. The experience is made enjoyable by the fact that the user does not need to worry about the intricate geometric details that would be necessary to produce a real mechanism. In this paper, we propose to start from such casual designs of mechanisms and turn them into a 3D model that can be printed onto widely available, inexpensive filament based 3D printers. Our intent is to empower the users of such tools with the ability to physically realize their mechanisms and see them operate in the real world. To achieve this goal we tackle several challenges. The input 2D mechanism allows for some parts to overlap during simulation. These overlapping parts have to be resolved into non‐intersecting 3D parts in the real mechanism. We introduce a novel scheme based on the idea of including moving parts into one another whenever possible. This reduces bending stresses on axles compared to previous methods. Our approach supports sliding parts and arbitrarily shaped mechanical parts in the 2D input. The exact 3D shape of the parts is inferred from the 2D input and the simulation of the mechanism, using boolean operations between shapes. The input mechanism is often simply attached to the background. We automatically synthesize a chassis by formulating a topology optimization problem, taking into account the stresses exerted by the mechanism on the chassis through time.

Abstract Fused Filament Fabrication is an additive manufacturing process by which a 3D object is created from plastic filament. The filament is pushed through a hot nozzle where it melts. The nozzle deposits plastic layer after layer to create the final object. This process has been popularized by the RepRap community. Several printers feature multiple extruders, allowing objects to be formed from multiple materials or colors. The extruders are mounted side by side on the printer carriage. However, the print quality suffers when objects with color patterns are printed – a disappointment for designers interested in 3D printing their colored digital models. The most severe issue is the oozing of plastic from the idle extruders: Plastics of different colors bleed onto each other giving the surface a smudged aspect, excess strings oozing from the extruder deposit on the surface, and holes appear due to this missing plastic. Fixing this issue is difficult: increasing the printing speed reduces oozing but also degrades surface quality – on large prints the required speed level become impractical. Adding a physical mechanism increases cost and print time as extruders travel to a cleaning station. Instead, we rely on software and exploit degrees of freedom of the printing process. We introduce three techniques that complement each other in improving the print quality significantly. We first reduce the impact of oozing plastic by choosing a better azimuth angle for the printed part. We build a disposable rampart in close proximity of the part, giving the extruders the opportunity to wipe oozing strings and refill with hot plastic. We finally introduce a toolpath planner avoiding and hiding most of the defects due to oozing, and seamlessly integrating the rampart. We demonstrate our technique on several challenging multiple color prints, and show that our tool path planner improves the surface finish of single color prints as well.

Fused Filament Fabrication (FFF) is the process of 3D printing objects from melted plastic filament. The hot plastic exits a nozzle and fuses with the part just below, adding a layer of material to the object being formed. However, filament can only be deposited on top of an existing surface. Therefore, overhangs require a disposable support structure to be printed, temporarily supporting the threads of plastic that would otherwise hang in empty space. Existing techniques for support generation fall into two categories: The first allow for very reliable prints by enclosing the bottom of the object in a dense structure, at the expense of increased material usage and build times. The second generate thin hierarchical structures connecting to the surface in a sparse number of points. This uses less material, at the expense of reliability: the part might become unstable, the structure itself may become difficult to print, the bottom surface quality degrades. The user therefore has to correct the structure and its parameters for each new object. We propose to exploit the ability of FFF printers to print bridges across gaps. Since bridges are always supported by pillars at their extremities, they are both stronger and more stable than hierarchical tree structures. Our technique first selects the points to support based on overhang and part stability during the entire print process. It then optimizes for a printable scaffolding composed of bridges and vertical pillars, supporting all points. The result is an automated support generation technique using little material while ensuring fine surface quality and stability during the printing process.