Wire Arc Additive Manufacturing (WAAM) is a metal 3D printing technology that deposits molten metal wire on a substrate to form desired geometries. Articulated robot arms are commonly used in WAAM to produce complex geometric shapes. However, they mostly rely on proprietary robot and weld control software that limits process tuning and customization, incorporation of third-party sensors, implementation on robots and weld controllers from multiple vendors, and customizable user programming. This paper presents a general open-source software architecture for WAAM that addresses these limitations. The foundation of this architecture is Robot Raconteur, an open-source control and communication framework that serves as the middleware for integrating robots and sensors from different vendors. Based on this architecture, we developed an end-to-end robotic WAAM implementation that takes a CAD file to a printed WAAM part and evaluates the accuracy of the result. The major components in the architecture include part slicing, robot motion planning, part metrology, in-process sensing, and process tuning. The current implementation is based on Motoman robots and Fronius weld controller, but the approach is applicable to other industrial robots and weld controllers. The capability of the WAAM tested is demonstrated through the printing of parts of various geometries and acquisition of in-process sensor data for motion adjustment.

The presence of gas pores in metal feedstock powder for additive manufacturing greatly affects the final AM product. Since current porosity analysis often involves lengthy X-ray computed tomography (XCT) scans with a full rotation around the sample, motivation exists to explore methods that allow for high throughput -- possibly enabling in-line porosity analysis during manufacturing. Through labelling pore pixels on single 2D radiographs of powders, this work seeks to simulate such future efficient setups. High segmentation accuracy is achieved by combining a model of X-ray attenuation through particles with a variant of the widely applied UNet architecture; notably, F1-score increases by $11.4\%$ compared to the baseline UNet. The proposed pore segmentation is enabled by: 1) pretraining on synthetic data, 2) making tight particle cutouts, and 3) subtracting an ideal particle without pores generated from a distance map inspired by Lambert-Beers law. This paper explores four image processing methods, where the fastest (yet still unoptimized) segments a particle in mean $0.014s$ time with F1-score $0.78$, and the most accurate in $0.291s$ with F1-score $0.87$. Due to their scalable nature, these strategies can be involved in making high throughput porosity analysis of metal feedstock powder for additive manufacturing.

Vertebrate animals benefit from a combination of rigidity for structural support and softness for adaptation. Similarly, integrating rigidity and softness can enhance the versatility of soft robotics. However, the challenges associated with creating durable bonding interfaces between soft and rigid materials have limited the development of hybrid robots. Existing solutions require specialized machinery, such as polyjet 3D printers, which are not commonly available. In response to these challenges, we have developed a 3D printing technique that can be used with almost all commercially available FDM printers. This technique leverages the common issue of underextrusion to create a strong bond between soft and rigid materials. Underextrusion generates a porous structure, similar to fibrous connective tissues, that provides a robust interface with the rigid part through layer fusion, while the porosity enables interlocking with the soft material. Our experiments demonstrated that this method outperforms conventional adhesives commonly used in soft robotics, achieving nearly 200\% of the bonding strength in both lap shear and peeling tests. Additionally, we investigated how different porosity levels affect bonding strength. We tested the technique under pressure scenarios critical to soft and hybrid robots and achieved three times more pressure than the current adhesion solution. Finally, we fabricated various hybrid robots using this technique to demonstrate the wide range of capabilities this approach and hybridity can bring to soft robotics. has context menu

Recently, vision-based tactile sensors (VBTSs) have gained popularity in robotics systems. The sensing mechanisms of most VBTSs can be categorised based on the type of tactile features they capture. Each category requires specific structural designs to convert physical contact into optical information. The complex architectures of VBTSs pose challenges for traditional manufacturing techniques in terms of design flexibility, cost-effectiveness, and quality stability. Previous research has shown that monolithic manufacturing using multi-material 3D printing technology can partially address these challenges. This study introduces the CrystalTac family, a series of VBTSs designed with a unique sensing mechanism and fabricated through rapid monolithic manufacturing. Case studies on CrystalTac-type sensors demonstrate their effective performance in tasks involving tactile perception, along with impressive cost-effectiveness and design flexibility. The CrystalTac family aims to highlight the potential of monolithic manufacturing in VBTS development and inspire further research in tactile sensing and manipulation.

The integration of artificial intelligence into agricultural practices, specifically through Consultation on Intelligent Agricultural Machinery Management (CIAMM), has the potential to revolutionize efficiency and sustainability in farming. This paper introduces a novel approach that leverages large language models (LLMs), particularly GPT-4, combined with multi-round prompt engineering to enhance decision-making processes in agricultural machinery management. We systematically developed and refined prompts to guide the LLMs in generating precise and contextually relevant outputs. Our approach was evaluated using a manually curated dataset from various online sources, and performance was assessed with accuracy and GPT-4 Scores. Comparative experiments were conducted using LLama-2-70B, ChatGPT, and GPT-4 models, alongside baseline and state-of-the-art methods such as Chain of Thought (CoT) and Thought of Thought (ThoT). The results demonstrate that our method significantly outperforms these approaches, achieving higher accuracy and relevance in generated responses. This paper highlights the potential of advanced prompt engineering techniques in improving the robustness and applicability of AI in agricultural contexts.

Data-driven research in Additive Manufacturing (AM) has gained significant success in recent years. This has led to a plethora of scientific literature to emerge. The knowledge in these works consists of AM and Artificial Intelligence (AI) contexts that have not been mined and formalized in an integrated way. It requires substantial effort and time to extract scientific information from these works. AM domain experts have contributed over two dozen review papers to summarize these works. However, information specific to AM and AI contexts still requires manual effort to extract. The recent success of foundation models such as BERT (Bidirectional Encoder Representations for Transformers) or GPT (Generative Pre-trained Transformers) on textual data has opened the possibility of expediting scientific information extraction. We propose a framework that enables collaboration between AM and AI experts to continuously extract scientific information from data-driven AM literature. A demonstration tool is implemented based on the proposed framework and a case study is conducted to extract information relevant to the datasets, modeling, sensing, and AM system categories. We show the ability of LLMs (Large Language Models) to expedite the extraction of relevant information from data-driven AM literature. In the future, the framework can be used to extract information from the broader design and manufacturing literature in the engineering discipline.

In this work, the novel, open-source humanoid robot, PANDORA, is presented where a majority of the structural elements are manufactured using 3D-printed compliant materials. As opposed to contemporary approaches that incorporate the elastic element into the actuator mechanisms, PANDORA is designed to be compliant under load, or in other words, structurally elastic. This design approach lowers manufacturing cost and time, design complexity, and assembly time while introducing controls challenges in state estimation, joint and whole-body control. This work features an in-depth description on the mechanical and electrical subsystems including details regarding additive manufacturing benefits and drawbacks, usage and placement of sensors, and networking between devices. In addition, the design of structural elastic components and their effects on overall performance from an estimation and control perspective are discussed. Finally, results are presented which demonstrate the robot completing a robust balancing objective in the presence of disturbances and stepping behaviors.

In simulation-based engineering design with time-consuming simulators, Gaussian process (GP) models are widely used as fast emulators to speed up the design optimization process. In its most commonly used form, the input of GP is a simple list of design parameters. With rapid development of additive manufacturing (also known as 3D printing), design inputs with 2D/3D spatial information become prevalent in some applications, for example, neighboring relations between pixels/voxels and material distributions in heterogeneous materials. Such spatial information, vital to 3D printed designs, is hard to incorporate into existing GP models with common kernels such as squared exponential or Mat\'ern. In this work, we propose to embed a generalized distance measure into a GP kernel, offering a novel and convenient technique to incorporate spatial information from freeform 3D printed designs into the GP framework. The proposed method allows complex design problems for 3D printed objects to take advantage of a plethora of tools available from the GP surrogate-based simulation optimization such as designed experiments and GP-based optimizations including Bayesian optimization. We investigate the properties of the proposed method and illustrate its performance by several numerical examples of 3D printed antennas. The dataset is publicly available at: https://github.com/xichennn/GP_dataset.

The growing complexity of power system management has led to an increased interest in reinforcement learning (RL). However, vanilla RL controllers cannot themselves ensure satisfaction of system constraints. Therefore, combining them with formally correct safeguarding mechanisms is an important aspect when studying RL for power system management. Integrating safeguarding into complex use cases requires tool support. To address this need, we introduce the Python tool CommonPower. CommonPower's unique contribution lies in its symbolic modeling approach, which enables flexible, model-based safeguarding of RL controllers. Moreover, CommonPower offers a unified interface for single-agent RL, multi-agent RL, and optimal control, with seamless integration of different forecasting methods. This allows users to validate the effectiveness of safe RL controllers across a large variety of case studies and investigate the influence of specific aspects on overall performance. We demonstrate CommonPower's versatility through a numerical case study that compares RL agents featuring different safeguards with a model predictive controller in the context of building energy management.

Compared to physics-based computational manufacturing, data-driven models such as machine learning (ML) are alternative approaches to achieve smart manufacturing. However, the data-driven ML's "black box" nature has presented a challenge to interpreting its outcomes. On the other hand, governing physical laws are not effectively utilized to develop data-efficient ML algorithms. To leverage the advantages of ML and physical laws of advanced manufacturing, this paper focuses on the development of a physics-informed machine learning (PIML) model by integrating neural networks and physical laws to improve model accuracy, transparency, and generalization with case studies in laser metal deposition (LMD).