The future of intelligent manufacturing machines involves autonomous selection of process parameters to maximize productivity while maintaining quality within specified constraints. To effectively optimize process parameters, these machines need to adapt to existing uncertainties in the physical system. This paper proposes a novel framework and methodology for feedrate optimization that is based on a physics-informed data-driven digital twin with quantified uncertainty. The servo dynamics are modeled using a digital twin, which incorporates the known uncertainty in the physics-based models and predicts the distribution of contour error using a data-driven model that learns the unknown uncertainty on-the-fly by sensor measurements. Using the quantified uncertainty, the proposed feedrate optimization maximizes productivity while maintaining quality under desired servo error constraints and stringency (i.e., the tolerance for constraint violation under uncertainty) using a model predictive control framework. Experimental results obtained using a 3-axis desktop CNC machine tool and a desktop 3D printer demonstrate significant cycle time reductions of up to 38% and 17% respectively, while staying close to the error tolerances compared to the existing methods.

Laser powder bed fusion (LPBF) is an additive manufacturing technique that is gaining popularity for producing metallic parts in various industries. However, parts produced by LPBF are prone to residual stress, deformation, cracks and other quality defects due to uneven temperature distribution during the LPBF process. To address this issue, in prior work, the authors have proposed SmartScan, a method for determining laser scan sequence in LPBF using a model-based and optimization-driven approach, rather than using heuristics, and applied it to simple 2D geometries. This paper presents a generalized SmartScan methodology that is applicable to arbitrary 3D geometries. This is achieved by: (1) expanding the thermal model and optimization approach used in SmartScan to multiple layers; (2) enabling SmartScan to process shapes with arbitrary contours and infill patterns within each layer and (3) providing SmartScan with global foresight to make it less myopic in its optimization. Sample 3D parts are printed using the proposed generalized SmartScan and compared to those printed using standard heuristic scan sequences. Reductions of up to 93% in temperature inhomogeneity, 87% in residual stress, and 26% in maximum deformation were observed, without significantly sacrificing print speed. However, SmartScan was found to cause minor (<5%) to significant (up to 20%) increases in surface roughness compared to the heuristic approaches, depending on the scan pattern used.

Cloud-based CNC is an emerging paradigm of Industry 4.0 where computer numerical control (CNC) functionalities are moved to the cloud and provided to manufacturing machines as a service. Among many benefits, C-CNC allows manufacturing machines to leverage advanced control algorithms running on cloud computers to boost their performance at low cost, without need for major hardware upgrades. However, a fundamental challenge of C-CNC is how to guarantee safety and reliability of machine control given variable Internet quality of service, especially on public Internet networks. We propose a three-tier redundant architecture to address this challenge. We then prototype tier one of the architecture on a 3D printer successfully controlled via C-CNC over public Internet connections, and discuss follow-on research opportunities.

Desktop fused filament fabrication (FFF) 3D printers have been growing in popularity among hobbyist and professional users as a prototyping and low-volume manufacturing tool. One issue these printers face is the inability to determine when a defect has occurred rendering the print unusable. Several techniques have been proposed to detect such defects but many of these approaches are tailored to one specific fault (e.g., filament runout/jam), use expensive hardware such as laser distance sensors, and/or use machine vision algorithms which are sensitive to ambient conditions, and hence can be unreliable. This paper proposes a versatile, reliable, and low-cost system, named MTouch, to detect millimeter-scale defects that tend to make prints unusable. At the core of MTouch is an actuated contact probe designed using a low-power solenoid, magnet, and hall effect sensor. This sensor is used to check for the presence, or absence, of the printed object at specific locations. The MTouch probe demonstrated 100% reliability, which was significantly higher than the 74% reliability achieved using a commercially available contact probe (the BLTouch). Additionally, an algorithm was developed to automatically detect common print failures such as layer shifting, bed separation, and filament runout using the MTouch probe. The algorithm was implemented on a Raspberry Pi mini-computer via an Octoprint plug-in. In head-to-head testing against a commercially available print defect detection system (The Spaghetti Detective), the MTouch was able to detect faults 44% faster on average while only increasing the print time by 8.49%. In addition, MTouch was able to detect faults The Spaghetti Detective was unable to identify such as layer shifting and filament runout/jam.

Control as a Service (CaaS) is an emerging paradigm where low-level control of a device is moved from a local controller to the Cloud, and provided to the device as an on-demand service. Among its many benefits, CaaS gives the device access to advanced control algorithms which may not be executable on a local controller due to computational limitations. As a step toward 3D printer CaaS, this paper demonstrates the control of a 3D printer by streaming low-level stepper motor commands (as opposed to high-level G-codes) directly from the Cloud to the printer. The printer is located at the University of Michigan, Ann Arbor, while its stepper motor commands are calculated using an advanced motion control algorithm running on Google Cloud computers in South Carolina and Australia. The stepper motor commands are sent over the Internet using the user datagram protocol (UDP) and buffered to mitigate transmission delays; checks are included to ensure accuracy and completeness of the transmitted data. All but one part printed using the cloud-based controller in both locations were hitch free (i.e., no pauses due to excessive transmission delays). Moreover, using the cloud-based controller, the parts printed up to 54% faster than using a standard local controller, without loss of accuracy.