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We consider two mathematical problems that are connected and occur in the layer-wise production process of a workpiece using wire-arc additive manufacturing. As the first task, we consider the automatic construction of a honeycomb structure, given the boundary of a shape of interest. In doing this, we employ Lloyd’s algorithm in two different realizations. For computing the incorporated Voronoi tesselation we consider the use of a Delaunay triangulation or alternatively, the eikonal equation. We compare and modify these approaches with the aim of combining their respective advantages. Then in the second task, to find an optimal tool path guaranteeing minimal production time and high quality of the workpiece, a mixed-integer linear programming problem is derived. The model takes thermal conduction and radiation during the process into account and aims to minimize temperature gradients inside the material. Its solvability for standard mixed-integer solvers is demonstrated on several test-instances. The results are compared with manufactured workpieces.
In certain additive manufacturing processes of industrial interest, the task arises to build up structures layer-wise in a purely vertical manner. The question arises how to construct such a structure in a convenient way so that it is structurally as stable as possible.
In this paper, we consider the automatic construction of a honeycomb structure, given the boundary of a shape of interest. In doing this we employ Lloyd’s algorithm in two different realisations. For computing the incorporated Voronoi tessellation we consider the use of a Delaunay triangulation or the Eikonal equation. As a main point of our paper, we give a comparison of these two methods. We show that one can make use of the arising graph of the honeycomb structure as input for a specific routing scheme that enhances printability when the printing material stays soft for some time during the printing process.