Session: AM3D1.1 - Current and Emerging Trends in AM

Paper Number: 160242

160242 - Nesting Algorithms for Optimal Laminated Additive Manufacturing 

The laminated object manufacturing (LOM) process is a rapid prototyping technology used to manufacture 3D solid objects with a sheet lamination process. The unique feature of this technology is its capacity to manufacture large, complicated geometrical parts with less cost of fabrication and operational time. It can have several possibilities for advancements in technology. OptiLAM is a LOM technique that does not involve hatching and decubing steps- it directly cuts the sliced layers from the feedstock without a bounding box or crosshatches outside the contour. This reduces waste material generation, if the layers are cut optimally from the feedstock.  As much as 80% of feedstock is wasted in LOM. Our main objective is to solve this problem by nesting the sliced layers onto the given feedstock. To optimize the usage of the stock sheet, nesting algorithms are employed to generate arrangements of the FPs(flat patterns, or, the layers) maximizing the area utilization. As the various laminates of the different layers will be nested on the roll in OptiLAM, this utilization will be the same as the nesting efficiency. Since this is a problem where 100% efficiency is unachievable, this paper takes a heuristic approach. A genetic algorithm is employed to generate nested solutions attempting to maximize the area utilization of a canvas of fixed size. This work outlines the OptiLAM technique, preprocessing steps(from slicing the 3D model to preparing the files to be nested), the structure and finally implementation of the genetic algorithm, verifying the feasability of the approach with the generation of early valid solutions (where the validity is defined by the absence of overlap between the FPs) and ultimately manufacturing the part using the nested results.

Presenting Author: Sudhanshu Dubey Kalinga Institute of Industrial Technology (KIIT)

Presenting Author Biography: Dr. Sudhanshu Dubey completed his PhD in Mechanical Engineering from IIT Bombay. He possesses a high level of expertise in the domain of additive manufacturing, with a focus in non-metal laminated object manufacturing.