The optimization of industrial processes remains a critical challenge, particularly when no mathematical formulation of objective functions or constraints is available. This study addresses this issue by proposing a surrogate-based, data-driven methodology for optimizing complex real-world manufacturing systems using only historical process data. Machine learning models are employed to approximate system behavior and construct surrogate models, which are integrated into a tailored metaheuristic approach: Data-Driven Differential Evolution with Multi-Level Penalty Functions and Surrogate Models, an adapted version of Differential Evolution suited to the characteristics of the studied process. The methodology is applied to an extrusion process in the tire manufacturing industry, with the goal of optimizing initialization parameters to reduce waste and production time. Results show that the surrogate-based optimization approach outperforms historical best configurations, achieving a 65\% reduction in initialization and setup time, while also significantly minimizing material waste. These findings highlight the potential of combining data-driven modeling and metaheuristic optimization for industrial processes where explicit formulations are unavailable.

We address the problem of object arrangement and scheduling for sequential 3D printing. Unlike the standard 3D printing, where all objects are printed slice by slice at once, in sequential 3D printing, objects are completed one after other. In the sequential case, it is necessary to ensure that the moving parts of the printer do not collide with previously printed objects. We look at the sequential printing problem from the perspective of combinatorial optimization. We propose to express the problem as a linear arithmetic formula, which is then solved using a solver for satisfiability modulo theories (SMT). However, we do not solve the formula expressing the problem of object arrangement and scheduling directly, but we have proposed a technique inspired by counterexample guided abstraction refinement (CEGAR), which turned out to be a key innovation to efficiency.

A novel autonomous chunk-based aerial additive manufacturing framework is presented, supported with experimental demonstration advancing aerial 3D printing. An optimization-based decomposition algorithm transforms structures into sub-components, or chunks, treated as individual tasks coordinated via a dependency graph, ensuring sequential assignment to UA Vs considering inter-dependencies and printability constraints for seamless execution. A specially designed hexacopter equipped with a pressurized canister for lightweight expandable foam extrusion is utilized to deposit the material in a controlled manner. To further enhance precise execution of the printing, an offset-free Model Predictive Control mechanism is considered compensating reactively for disturbances and ground effect during execution. Additionally, an interlocking mechanism is introduced in the chunking process to enhance structural cohesion and improve layer adhesion. Extensive experiments demonstrate the framework's effectiveness in constructing precise structures of various shapes, while seamlessly adapting to practical challenges, proving its potential for a transformative leap in aerial robotic capability for autonomous construction. A video with the overall demonstration can be found here: https://youtu.be/WC1rLMLKEg4. Preprint submitted to Journal of Automation In Construction February 27, 2025 1. Introduction In recent times, ground breaking advancement in additive manufacturing, seamlessly integrated with autonomous robotics, are unlocking an exciting frontier in next generation construction and manufacturing process. Additive manufacturing has demonstrated a paradigm shift impact, addressing complex manufacturing processes with unprecedented precision and efficiency. Its transformative potential is becoming increasingly evident as it evolves and finds applications across a wide range of industries [1, 2, 3], while simultaneously paving the way for further innovations in the future. An intriguing development is its recent integration into the construction industry, capitalizing on its ability to automate construction processes, provide extensive design flexibility, and construct intricate structures designed using Computer-Aided Design (CAD) software [4, 5]. Numerous studies have demonstrated the design and deployment of large-scale robotic arms and gantry systems for printing building components and even entire houses using a variety of base materials [6]. A key advantage of such methods is their ability to adapt with high level of automation throughout the construction process, making them particularly well-suited for deployment in remote, inaccessible, and harsh environments[7, 8]. Notable examples include disaster-stricken areas, such as regions impacted by fires and earthquakes, where the rapid construction of shelters and basic infrastructure is imperative.

This article introduces an artistic research project that utilises artist-in-residency and exhibition as methods for exploring the possibilities of robotic 3D printing and ceramics. The interdisciplinary project unites artists and architects to collaborate on a proposed curatorial concept and Do-It-With-Others (DIWO) technological development. Constraints include material, specifically local clay, production technique, namely 3D printing with a robotic arm, and kiln size, as well as an exhibition concept that is further elaborated in the next chapter. The pictorial presents four projects as case studies demonstrating how the creatives integrate these constraints into their processes. This integration leads to the subsequent refinement and customization of the robotic-ceramics interface, aligning with the practitioners' requirements through software development. The project's focus extends beyond artistic outcomes, aiming also to advance the pipeline of 3D robotic printing in clay, employing a digitally controlled material press that has been developed in-house, with its functionality refined through practice.

This article introduces an experimental emulation of a novel chunk-based flexible multi-DoF aerial 3D printing framework. The experimental demonstration of the overall autonomy focuses on precise motion planning and task allocation for a UAV, traversing through a series of planned space-filling paths involved in the aerial 3D printing process without physically depositing the overlaying material. The flexible multi-DoF aerial 3D printing is a newly developed framework and has the potential to strategically distribute the envisioned 3D model to be printed into small, manageable chunks suitable for distributed 3D printing. Moreover, by harnessing the dexterous flexibility due to the 6 DoF motion of UAV, the framework enables the provision of integrating the overall autonomy stack, potentially opening up an entirely new frontier in additive manufacturing. However, it's essential to note that the feasibility of this pioneering concept is still in its very early stage of development, which yet needs to be experimentally verified. Towards this direction, experimental emulation serves as the crucial stepping stone, providing a pseudo mockup scenario by virtual material deposition, helping to identify technological gaps from simulation to reality. Experimental emulation results, supported by critical analysis and discussion, lay the foundation for addressing the technological and research challenges to significantly push the boundaries of the state-of-the-art 3D printing mechanism.

Many different worldwide initiatives are promoting the transformation from machine dominant manufacturing to digital manufacturing. Thus, to achieve a successful transformation to Industry 4.0 standard, manufacturing enterprises are required to implement a clear roadmap. However, Small and Medium Manufacturing Enterprises (SMEs) encounter many barriers and difficulties (economical, technical, cultural, etc.) in the implementation of Industry 4.0. Although several works deal with the incorporation of Industry 4.0 technologies in the area of the product and supply chain life cycles, which SMEs could use as reference, this is not the case for the customer life cycle. Thus, we present two contributions that can help the software engineers of those SMEs to incorporate Industry 4.0 technologies in the context of the customer life cycle. The first contribution is a methodology that can help those software engineers in the task of creating new software services, aligned with Industry 4.0, that allow to change how customers interact with enterprises and the experiences they have while interacting with them. The methodology details a set of stages that are divided into phases which in turn are made up of activities. It places special emphasis on the incorporation of semantics descriptions and 3D visualization in the implementation of those new services. The second contribution is a system developed for a real manufacturing scenario, using the proposed methodology, which allows to observe the possibilities that this kind of systems can offer to SMEs in two phases of the customer life cycle: Discover & Shop, and Use & Service.

Semantically rich descriptions of manufacturing machines, offered in a machine-interpretable code, can provide interesting benefits in Industry 4.0 scenarios. However, the lack of that type of descriptions is evident. In this paper we present the development effort made to build an ontology, called ExtruOnt, for describing a type of manufacturing machine, more precisely, a type that performs an extrusion process (extruder). Although the scope of the ontology is restricted to a concrete domain, it could be used as a model for the development of other ontologies for describing manufacturing machines in Industry 4.0 scenarios. The terms of the ExtruOnt ontology provide different types of information related with an extruder, which are reflected in distinct modules that constitute the ontology. Thus, it contains classes and properties for expressing descriptions about components of an extruder, spatial connections, features, and 3D representations of those components, and finally the sensors used to capture indicators about the performance of this type of machine. The ontology development process has been carried out in close collaboration with domain experts.

The growing trends in automation, Internet of Things, big data and cloud computing technologies have led to the fourth industrial revolution (Industry 4.0), where it is possible to visualize and identify patterns and insights, which results in a better understanding of the data and can improve the manufacturing process. However, many times, the task of data exploration results difficult for manufacturing experts because they might be interested in analyzing also data that does not appear in pre-designed visualizations and therefore they must be assisted by Information Technology experts. In this paper, we present a proposal materialized in a semantic-based visual query system developed for a real Industry 4.0 scenario that allows domain experts to explore and visualize data in a friendly way. The main novelty of the system is the combined use that it makes of captured data that are semantically annotated first, and a 2D customized digital representation of a machine that is also linked with semantic descriptions. Those descriptions are expressed using terms of an ontology, where, among others, the sensors that are used to capture indicators about the performance of a machine that belongs to a Industry 4.0 scenario have been modeled. Moreover, this semantic description allows to: formulate queries at a higher level of abstraction, provide customized graphical visualizations of the results based on the format and nature of the data, and download enriched data enabling further types of analysis.

The future of 3D printing utilizing unmanned aerial vehicles (UAVs) presents a promising capability to revolutionize manufacturing and to enable the creation of large-scale structures in remote and hard- to-reach areas e.g. in other planetary systems. Nevertheless, the limited payload capacity of UAVs and the complexity in the 3D printing of large objects pose significant challenges. In this article we propose a novel chunk-based framework for distributed 3D printing using UAVs that sets the basis for a fully collaborative aerial 3D printing of challenging structures. The presented framework, through a novel proposed optimisation process, is able to divide the 3D model to be printed into small, manageable chunks and to assign them to a UAV for partial printing of the assigned chunk, in a fully autonomous approach. Thus, we establish the algorithms for chunk division, allocation, and printing, and we also introduce a novel algorithm that efficiently partitions the mesh into planar chunks, while accounting for the inter-connectivity constraints of the chunks. The efficiency of the proposed framework is demonstrated through multiple physics based simulations in Gazebo, where a CAD construction mesh is printed via multiple UAVs carrying materials whose volume is proportionate to a fraction of the total mesh volume.

Robot-assisted 3D printing has drawn a lot of attention by its capability to fabricate curved layers that are optimized according to different objectives. However, the support generation algorithm based on a fixed printing direction for planar layers cannot be directly applied for curved layers as the orientation of material accumulation is dynamically varied. In this paper, we propose a skeleton-based support generation method for robot-assisted 3D printing with curved layers. The support is represented as an implicit solid so that the problems of numerical robustness can be effectively avoided. The effectiveness of our algorithm is verified on a dual-material printing platform that consists of a robotic arm and a newly designed dual-material extruder. Experiments have been successfully conducted on our system to fabricate a variety of freeform models.