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Subtractive Manufacturing

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lightbulbAbout this topic
Subtractive manufacturing is a manufacturing process that involves removing material from a solid block or workpiece to create a desired shape or design. This is typically achieved through techniques such as machining, milling, and turning, where material is systematically cut away to achieve precise dimensions and surface finishes.
lightbulbAbout this topic
Subtractive manufacturing is a manufacturing process that involves removing material from a solid block or workpiece to create a desired shape or design. This is typically achieved through techniques such as machining, milling, and turning, where material is systematically cut away to achieve precise dimensions and surface finishes.

Key research themes

1. What are the optimal subtractive manufacturing techniques for producing biocompatible metallic implants with superior surface and mechanical properties?

This research area focuses on identifying and validating subtractive manufacturing processes that meet the stringent requirements of medical implant fabrication, such as dimensional accuracy, biocompatibility, surface integrity, and fatigue strength. It matters because surgical implants require precise geometries and surfaces to ensure proper mechanical performance and biological integration, while minimizing costs and environmental impacts.

Key finding: This paper systematically reviews both traditional (turning, drilling, milling, multi-axis CNC) and non-traditional (abrasive water jet machining, laser beam machining, ultrasonic machining, electric discharge machining, EDM)... Read more
Key finding: Investigates an integrated laser powder bed fusion (LPBF) additive and high-speed micro-machining subtractive process for Inconel 718, demonstrating that micro-machining post-processing significantly improves surface finish... Read more
Key finding: Highlights industrial hybrid machines that integrate subtractive and additive manufacturing for producing complex, high-quality parts. The review emphasizes the necessity of subtractive finishing operations to address surface... Read more
Key finding: Presents a novel hybrid manufacturing system combining directed energy deposition additive processes with forming operations, where subtractive machining refines geometry and improves surface roughness. The study demonstrates... Read more

2. How can additive and subtractive manufacturing processes be effectively integrated to optimize production flexibility and complexity management in industrial settings?

This theme explores operational and production management perspectives on the interplay between additive and subtractive manufacturing for enhanced manufacturing flexibility, cost efficiency, and complexity handling. It focuses on strategic decision-making in hybrid production environments, cost modeling, and the scalability of additive technologies alongside conventional subtractive processes in manufacturing firms, pertinent to mass personalization and complex part fabrication.

Key finding: Proposes a complexity-driven methodology to evaluate and select between additive and subtractive manufacturing processes, demonstrating that AM offers 'complexity-for-free'—allowing production of intricate geometries without... Read more
Key finding: Through extensive literature review and model development, this work addresses operational challenges in integrating additive manufacturing into traditional production systems. It models production costs and proposes... Read more
Key finding: Develops a conceptual framework quantifying the impact of additive manufacturing on production system flexibility, particularly volume and mix flexibility. The case study illustrates how integrating AM with conventional... Read more
Key finding: Introduces a rigorous yielded cost metric that accounts for yield loss to evaluate effective unit cost in sequential manufacturing processes. This method offers a consistent way to apportion costs across steps including... Read more
Key finding: Demonstrates the economic and technical viability of using additive manufacturing to produce polymeric spare parts on demand, thus reducing inventory requirements in preventive maintenance. This work reveals integration... Read more

3. What novel design and fabrication methodologies leverage subtractive manufacturing tools for efficient shape simplification and precision in complex product manufacturing?

This area focuses on computational design and fabrication strategies that simplify complex 3D models into manufacturable components compatible with subtractive manufacturing technologies such as CNC milling. It addresses geometric simplification, toolpath generation, and assembly facilitation using subtractive approaches, providing insights for manufacturing practitioners aiming to translate complex digital designs into physical realizations effectively.

Key finding: Develops a pipeline that automatically simplifies complex 3D shapes into polygonal flat facets with constrained dihedral angles compatible with V-Groove CNC milling cutters. The method ensures manufacturability by enabling... Read more
Key finding: Describes a kinematic-based coining process to imprint ultra-precision, meso-scale features onto metallic blanks without generating chips or compromising material structure. By controlling total thickness variation to under... Read more
Key finding: Proposes an integrated methodology employing topology optimization, design for manufacturing, and design for additive manufacturing to redesign aircraft components for respective processes. By comparing mechanical, economic,... Read more

All papers in Subtractive Manufacturing

Additive manufacturing, commonly known as 3D Printing, is a production method of rising popularity. The method works by adding layers of material, in contrast to subtracting, which is the dominating method today. The objective of this... more
Additive manufacturing, commonly known as 3D Printing, is a production method of rising popularity. The method works by adding layers of material, in contrast to subtracting, which is the dominating method today. The objective of this... more
Hybrid machine tools combining additive and subtractive processes have arisen as a solution to the increasing manufacture requirements, boosting the potentials of both technologies, while compensating and minimizing their limitations.... more
Hybrid Manufacturing combines the advantages of Additive Manufacturing (AM) and Subtractive Manufacturing on a single machine. Although previous research has provided a good background of the manufacturing parameters, the analysis is... more
Figure 1: From left to right: the original model; the result of the automatic simplification (Section 3); the clean model after spurious facets removal (Section 4); its unfolding for fabrication using CNC milling machines.
Goniochromatic materials and objects appear to have different colors depending on viewing direction. This occurs in nature, such as in wood or minerals, and in human-made objects such as metal and effect pigments. In this paper, we... more
This work presents a new approach to simplify objects. It is restricted to orthogonal pseudo-polyhedra (OPP) and binary volumes. The method produces a level-of-detail (LOD) sequence of OPP and it is incremental. Any object in this... more
Update. At the conference, Jack Snoeyink found a path with length approximately 2.72 π. Vishal Verma, a graduate student at UNC Chapel Hill, joined him [VS07] to improve this to < 2.44 π for a teardrop-shaped path depicted in Figure 2.
Figure 1: Our processing pipeline in a nutshell (left to right): we first compute the rotation axis on the input mesh; we then partition the mesh in millable height-field portions (including the top and bottom ones) taking also into... more
This work presents a new approach to simplify objects. It is restricted to orthogonal pseudo-polyhedra (OPP) and binary volumes. The method produces a level-of-detail (LOD) sequence of OPP and it is incremental. Any object in this... more
A polyhedron can be unfolded to a net, i.e., an unfolding without overlapping, by carefully cutting along the surface. If the cuts are restricted only on the edges of the polyhedron, where should the cuts be? This is called an... more
Cut along the surface of a polyhedron and unfold it to a planar structure without overlapping is known as Unfolding Polyhedra problem which has been extensively studied in the mathematics literature for centuries. However, whether there... more
In this paper, we investigate the problem that asks if there exists a net of a polycube that is exactly a rectangle with slits. For this nontrivial question, we show affirmative solutions. First, we show some concrete examples: (1) no... more
Rapid progresses of 3D depth sensing and 3D printing technologies make digital fabrication an affordable technology for general public on daily life. Both experienced and novice users, who want to design and create new 3D geometric... more
We introduce here a pipeline for simplifying digital 3D shapes with the aim of fabricating them using 2D polygonal flat parts. Our method generates shapes that, once unfolded, can be fabricated with CNC milling machines using special... more
We propose an optimization framework for 3D printing that seeks to save printing time and the support material required to print 3D shapes. Three-dimensional printing technology is rapidly maturing and may revolutionize how we manufacture... more
We obtain results for three questions regarding vertex unfoldings of orthogonal polyhedra. The (positive) first result is a simple proof that all genus-0 and genus-1 orthogonal polyhedra have grid vertex unfoldings. The (negative) second... more
In this invited paper, we are going to present an ongoing collaboration with a local artist, Aurelie Mourier. The artist works with voxel shapes and this led our digital geometry team to develop new shape modeling tools and explore a... more
Generally applications in computer graphics use very high detailed models. These models are too complex for the limited hardware capacity and take much time to render and to transmit. Related fields can benefit from simplification of... more
A well-studied problem is that of unfolding a convex polyhedron into a simple planar polygon. In this paper, we study the limits of unfoldability. We give an example of a polyhedron with convex faces that cannot be unfolded by cutting... more
This paper presents experimental research on the Computer Numerical Control (CNC) routing of a traditional motif collected from Ţara Bârsei (Transylvania region) using two methods, namely, engraving (Engrave) and carving (V-Carve). The... more
This paper deals with PLA folding strategies: in particular, the accurate evaluation of the area used by folded PLA's is presented. Criteria are proposed to choose the best folding strategy among those considered, without performing all... more
Digital fabrication devices are powerful tools for creating tangible reproductions of 3D digital models. Most available printing technologies aim at producing an accurate copy of a tridimensional shape. However, fabrication technologies... more
Mesh segmentation has become an important step in medel understanding and can be used as a usefu1 teol for different applications, for instance, modeling and reverse engineering. We present mesh segmentation teehnique based on an... more
Composite laminates are made of multiple layers of fibrous material, each layer being formed by laying tapes of various widths on subregions of the planar development of the surface. The tapes are laid only along a certain direction, thus... more
Automatic maker is meant as a device to produce (or compose) things by itself, by a model, customization or a program. Nowadays the most advanced automatic makers in mass use are 3D-printers.The purpose of the paper is to present methods... more
Digital fabrication devices are powerful tools for creating tangible reproductions of 3D digital models. Most available printing technologies aim at producing an accurate copy of a tridimensional shape. However, fabrication technologies... more
Digital fabrication devices are powerful tools for creating tangible reproductions of 3D digital models. Most available printing technologies aim at producing an accurate copy of a tridimensional shape. However, fabrication technologies... more
Digital fabrication devices are powerful tools for creating tangible reproductions of 3D digital models. Most available printing technologies aim at producing an accurate copy of a tridimensional shape. However, fabrication technologies... more
We introduce a pipeline for simplifying digital 3D shapes and fabricate them using 2D polygonal flat parts. Our method generates shapes that, once unfolded, can be fabricated with CNC milling machines using special tools called V-Grooves.... more
We introduce here a pipeline for simplifying digital 3D shapes with the aim of fabricating them using 2D polygonal flat parts. Our method generates shapes that, once unfolded, can be fabricated with CNC milling machines using special... more
An unfolding of a polyhedron P is a obtained by cutting P along its edges and flattening it into the plane. Given an unfolding of a polyhedron P , we define its dual unfolding, which is an unfolding of the dual of P . We investigate the... more
Tracing the trajectory of stereotomy through millennia of practice, an extrapolation is presented that stereotomy will serve increased formal and structural complexity. The addition of robotic carving to stereotomy also removes the... more
This paper deals with PLA folding strategies: in particular, the accurate evaluation of the area used by folded PLA's is presented. Criteria are proposed to choose the best folding strategy among those considered, without performing all... more
Tra i programmi di modellazione e el macchine il dialogo non è sempre semplice. I programmi di raccordo, infatti sono un vero e proprio collo di bottiglia nelle quali molte idee progettuali possono andare perdute per eccessiva... more
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