Optimizing the multi-part layout to minimize the empty travel distance of nozzle

doi:10.11996/JG.j.2095-302X.2023061239

Abstract

Abstract:

The layout of multi-part in the printing chamber often directly impacts the efficiency and capability of batch manufacturing for fused filament fabrication (FFF). Meanwhile, the total empty travel distance of the printing nozzle exerts a significant impact on the efficiency and capability mentioned above. Therefore, an optimized layout method for multi-part was proposed, taking into account the empty travel distance. The method improved the efficiency of FFF's batch manufacturing and the printing chamber's available space by reducing the empty travel distance of the printing nozzle between each part. Firstly, to balance the efficiency (such as the acceleration of geometric interference detection) and the accuracy of empty travel distance calculation, the proposed approach constructed the corresponding voxel-based surrogate model layer by layer for each part. Then, based on a greedy strategy and PSO, this paper proposed a method for determining the order and position of each voxel-based surrogate model's placement pair by pair. Finally, the voxel-based surrogate models were replaced with their corresponding parts, and the input part set was compactly arranged. Experiments were conducted on a set of complex-shaped parts. The results showed that the proposed method could reduce the total empty distance of the printing nozzle by 31.17% compared to Magics under the same measuring standard. Furthermore, compared with the layout function in existing commercial software, this method exhibited enormous potential for significantly reducing the total empty distance of the printing nozzle for batch manufacturing with FFF, especially for the set of complex-shaped parts.

Key words: batch manufacturing, voxel-based surrogate model, part layout optimization, fused filament fabrication, 3D printing

CLC Number:

TB23

XING Xiao-yue, TAO Xiu-ting, WANG Shu-fang, PAN Wan-bin. Optimizing the multi-part layout to minimize the empty travel distance of nozzle[J]. Journal of Graphics, 2023, 44(6): 1239-1250.

Figures/Tables 22

Fig. 1 The empty travel distance of the nozzle between two parts ((a) Sliced two parts; (b) The empty travel distance of the nozzle moving in layer one; (c) The total empty travel distance)

Fig. 2 Different ways of representing parts in layout work

Fig. 3 The flow chart of the method in this paper

Fig. 4 Quickly construct the voxel-based surrogate model of input parts layer by layer ((a) Reading information; (b) Marking of overhanging areas; (c) Axial containment box; (d) Layer by layer voxelization; (e) Obtaining surface voxels; (f) Surrogate model; (g) Surrogate model (self-supporting); (h) Attribute representation of voxels)

Fig. 5 Empty travel distance of voxel-based surrogate models ((a) Total empty travel distance between models; (b) Single empty travel distance)

Fig. 6 The layout sequence and spatial position of the voxel-based surrogate model are determined based on greedy strategy

Fig. 7 Improved Particle Swarm Optimization algorithm

Fig. 8 The freedom of surrogate model

Fig. 9 Global optimal update constraints

Fig. 10 Optimize the finding direction of particle

Fig. 11 Optimize the velocity direction of α

Fig. 12 Example of surrogate model spatial position optimization procedure ((a) 20 particles; (b) Optimization example)

Fig. 13 The input parts of Experiment Ⅰ

Fig. 14 Layout effect of experiment Ⅰ

Fig. 15 The input parts of experiment Ⅱ

Fig. 16 Some surrogate models of experiment Ⅱ

Fig. 17 Layout effect of experiment Ⅱ

Table 1 Method comparison with several research work

方法	布局优化过程中零件表示方法	优化过程中考虑打印方向	逐层分析布局时零件间空行程	自支撑区域下方空间利用	零件堆叠放置
文献[4]	零件本身	否	是	否	否
文献[12]	投影多边形	是	否	否	否
文献[15]	零件包围盒	是	DLP打印，不适用	否	是
本文	每层外轮廓体素	否	是	是	否

Table 2 Empty travel distance under different layout sequences

实验模型	批量制造模型数量	平均零件空行程	布局序列	总空行程 (mm)
实验Ⅱ	15	111.5	体积	1 672
	15	104.2	高度	1 563
	15	113.7	随机	1 706
	15	103.4	投影面积	1 551
	15	73.1	贪心(本文)	1 096

Fig. 18 Experiment Ⅰ layout effect comparison ((a) This paper; (b) Magics)

Fig. 19 Experiment Ⅱ layout effect comparison ((a) This paper; (b) Magics)

Table 3 Layout comparison experiments with Magics

实验模型	总空行程长度(mm)			预计批量制造时长(min)
实验模型	本文	Magics	减少比例(%)	本文	Magics	优化时长
实验Ⅰ	583	847	31.17	103	123	20
实验Ⅱ	1027	1483	30.75	263	286	23

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