{"id":182000,"date":"2021-09-28T09:43:01","date_gmt":"2021-09-28T09:43:01","guid":{"rendered":"http:\/\/facfox.com\/news\/?p=182000"},"modified":"2021-09-07T10:24:36","modified_gmt":"2021-09-07T10:24:36","slug":"time-for-am-factories-to-get-in-aisync","status":"publish","type":"post","link":"https:\/\/facfox.com\/news\/time-for-am-factories-to-get-in-aisync\/","title":{"rendered":"Time for AM factories to get in AiSync"},"content":{"rendered":"

On the topic of AM automation, London-based Ai Build needs no introduction. The company, which has brought to market a large-scale robotic 3D print<\/a>ing<\/a> platform, was founded with the express goal of solving automation-related challenges associated with additive manufacturing through its AiSync software platform.<\/p>\n

Many across AM will be familiar with Ai Build for impressive collaborations within the architecture<\/a> and design worlds\u2014including an amazing 57-square-meter pavilion at the Venice Biennale in 2018\u2014but Ai Build is a technology company at its core, one with goals to continually advance and adapt to the market and its needs. In the following interview with Ai Build Co-Founder Daghan Cam, we learn about the company\u2019s automation mission with an increasing focus on industrial sectors like aerospace<\/a> and automotive<\/a>, as well as its AiSync software that automates large-scale additive manufacturing.<\/p>\n

Ai Build\u2026ing something new<\/h2>\n

Ai Build was founded in 2015 by Daghan Cam and Michail Desyllas, two innovative minds with backgrounds in architecture<\/a>.<\/p>\n

\u201cWe could see a big potential for additive manufacturing in various industrial application<\/a>s,\u201d Cam tells us. \u201cBut at the same time, we were frustrated with the fact that the technology didn\u2019t scale up well for the application<\/a>s we wanted, like architecture<\/a> and construction. Every minor problem in traditional desktop size 3D print<\/a>ing<\/a> is multiplied in large-format AM by a factor of 10 or more, making the entire process from design to finished part<\/a> extremely hard. That\u2019s why not many people have even considered 3D print<\/a>ing<\/a> at such large scales until recently.<\/p>\n

<\/p>\n

\u201cOur start<\/a>ing point was to investigate what makes AM, part<\/a>icularly in large format, so inaccessible. It didn\u2019t take long to understand that the lack of automation was the biggest barrier, by far. We were seeing days or even weeks of manual toolpath engineering attempts for fabricability of part<\/a>s and failure rates were about 40 to 60 percent, which was totally unacceptable. We broke down the process to understand where exactly the lack of automation was coming from. We looked at what happens before printing begins: how users are optimizing their designs, how process parameters are selected and how designs are processed through slicing software. At the time, these steps were very much based on the process knowledge of machine operators combined with lots of trial and error. We thought there could be a better way to do it, an automated way to achieve consistent results with additive.\u201d That, Cam says, is how he and Desyllas came up with the AiSync platform for autonomous large scale 3D print<\/a>ing<\/a>.<\/p>\n

Ai Build\u2019s solution<\/h2>\n

Ai Build\u2019s solution to large-scale additive manufacturing consists of a few components: the AiSync software, an FFF\/FGF based polymer extrusion system, an optional enclosure for environment<\/a>al control and a robotic arm. This multi-component configuration allows the company to develop large-scale 3D print<\/a>ing<\/a> features for a wide range of hardware solutions. At the core of Ai Build\u2019s recommended hardware setup is an industrial robotic arm from KUKA, a manufacturer of industrial robots and solutions for factory automation, with UK headquart<\/a>ers in Wednesbury, West Midlands.<\/p>\n

Cam explains: \u201cWe needed a very robust actuator that should be fully reliable and never fail. In order to achieve that 100% guarantee of success with the hardware, we part<\/a>nered with KUKA, as official system part<\/a>ners, who are very well known for high precision and highly reliable industrial robotic arms.\u201d<\/p>\n

<\/p>\n

The second key component on the hardware side is the AiMaker, the company\u2019s own extrusion system, capable of extruding thermoplastics and composites at a rapid rate of 3 kg per hour. \u201cDeveloping an autonomous 3D print<\/a>ing<\/a> technology is like developing an autonomous car. You cannot build a self-driving software and install it on any car in your backyard. The hardware needs to support the software with specific performance, sensors, cameras and computers.\u201d<\/p>\n

Cam says of choosing to develop a new extrusion system for large-format AM: \u201cThe existing extruders on the desktop 3D print<\/a>ing<\/a> market were too slow, too unreliable, and they didn\u2019t have the electronic components required for real-time control. So we built the AiMaker from scratch, which is to date the world\u2019s fastest FFF extruder on the market. Luckily, this gap for commercially available hardware components for large format AM has been filled in the last couple of years. Several European and American OEMs have released powerful large-scale 3D print<\/a>ers and today there is a healthy number of hardware options to choose from in this new and fast-growing AM category.\u201d<\/p>\n

All hardware components that are compatible with Ai Build\u2019s autonomous large-scale 3D print<\/a>ing<\/a> technology, are equipped with an array of sensors, cameras and computers which communicate with the AiSync software.<\/p>\n

AiSync: the key to the puzzle<\/h2>\n

AiSync, in the simplest terms, is a cloud-based software that takes design files and generates optimized machine instructions for large-scale 3D print<\/a>ing<\/a> automatically. The software makes additive manufacturing of large components such as molds, jigs, fixtures and end-use part<\/a>s as easy as clicking a few buttons on a web platform.<\/p>\n

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\u201cThe first thing that sets AiSync apart<\/a> from conventional 3D print<\/a>ing<\/a> software packages is that it takes full advantage of the additional degrees of freedom that come with the robotic arms,\u201d Cam says.<\/p>\n

\u201c3D print<\/a>ing<\/a> typically works in a linear layer-by-layer fashion<\/a>, so by moving the extruder in three dimensional space without constraining ourselves to flat layers, we can produce very efficient structures in much shorter timeframes and in higher quality. AiSync\u2019s multi-axis motion planning features allow our users to achieve structurally optimized 3D infills, non-planar slicing and even non-planar hybrid additive-subtractive treatment of surfaces with minimal effort.<\/p>\n

<\/p>\n

\u201cWith additional degrees of freedom, however, comes the challenge of toolpath design and optimization, because there are almost infinite ways to create a path in three-dimensional search space. AiSync uses analysis and simulation tools with high computing power on the cloud to determine the optimal toolpath for a given project within seconds, eliminating the need for excessive human labor and time-consuming trial and error.\u201d<\/p>\n

In addition to automating this part<\/a> of the additive manufacturing preparation, AiSync also plays an important role during the printing process. \u201cThe second aspect of the software that increases the level of automation dramatically is real-time communication with robots,\u201d Cam continues. \u201cMost 3D print<\/a>ers on the market take a G-code file and blindly execute it without having any control over that process, which is the exact opposite of autonomous manufacturing. Essentially, if anything unexpected happens, the process will fail, which is highly likely in large-scale AM. For this reason, we abandoned G-code and developed a completely new machine control process from scratch that is resilient to environment<\/a>al, material and hardware-related inconsistencies.\u201d The robots are driven by AiSync exchange data with a computer bi-directionally in real-time. Ai Build refers to this edge device as the AiSync Printer-Server which gives the ability to detect and compensate for common problems on the fly, with significant savings on time and materials.<\/p>\n

\u201cAs a result of AiSync\u2019s powerful simulation and optimization capabilities, our users achieve high quality production part<\/a>s in short amounts of time without even noticing the difficulties associated with large-scale additive manufacturing.\u201d<\/p>\n

Opening up AiSync<\/h2>\n

One of Ai Build\u2019s latest (and very exciting) announcements is that it is working to open up its technology to other manufacturing companies. Cam says: \u201cInitially AiSync was developed for the AiMaker, but more recently, we start<\/a>ed integrating it with other industrial 3D print<\/a>ers. We have already part<\/a>nered with several hardware manufacturers and that is keeping us very busy these days.\u201d At the moment, these integrations will be focused on other large-scale multi-axis 3D print<\/a>ers, though Cam says most of its processes can also be used for gantry 3D print<\/a>ing<\/a> systems.<\/p>\n

<\/p>\n

\u201cWe have announced our first part<\/a>nership on AiSync with Weber Additive, a German manufacturer of industrial 3D print<\/a>ers with more than 100 years of experience in machine development and manufacturing\u201d Cam reveals. \u201cBy combining the advanced control and monitoring features of AiSync with powerful industrial machines built by Weber, we are bringing to market highly automated and robust large-scale additive manufacturing solutions for heavy industrial application<\/a>s.\u201d<\/p>\n

Cam exclusively anticipates that the company will soon be unveiling the first AiSync powered Weber machine\u2014a multi-axis large-scale 3D print<\/a>er including a Kuka robot and a Weber AE020 pellet extrusion system. \u201cThis part<\/a>nership allows us to scale our operations in key industrial markets such as automotive<\/a> and aerospace<\/a>,\u201d he says.<\/p>\n

Envisioning the future<\/h2>\n

Down the line, Cam has a clear vision for how the Factory of the Future could play out, one in which automation drives lights-out production and additive is the key manufacturing process. \u201cThe advantages of additive are quite obvious to us: it\u2019s the most material-efficient way to do things, and it\u2019s also very capital efficient: you don\u2019t need expensive tooling,\u201d he states.<\/p>\n

\u201cWhat became very clear with COVID-19 is that AM is also the most efficient technology for the supply chain,\u201d he continues. \u201cIt eliminates transportation and storage because everything is done on demand. The biggest obstacle holding back the technology right now is the lack of automation. At Ai Build we are constantly asking ourselves what needs to change to achieve higher levels of automation and we are working closely with our industrial part<\/a>ners to accelerate our move towards autonomous lights-out manufacturing.<\/p>\n

\u201cOne key technology that needs to be embraced by manufacturers to increase automation is cloud connectivity. Before COVID-19, highly regulated industries like aerospace<\/a> were concerned about storing their data on the cloud, but now that is loosening up a bit with the increasing desire for automation. Cloud, when done correctly, can be more secure than on-premise solutions. This is already proven in other services like CRM platforms and accounting software that became almost entirely cloud-based in the last few years. Our mission at Ai Build is to enable the factories of the future that are autonomous, cloud-connected and primarily additive. There is of course a lot to do, but we are moving rapidly in that direction.\u201d<\/p>\n

*This art<\/a>icle first appeared in 3dpbm\u2018s AM Focus eBook on Automation. Read the entire issue here.<\/em><\/p>\n

<\/div>\n
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<\/div>\n<\/div>\n

* This article is reprinted from 3D Printing Media Network<\/a>. If you are involved in infringement, please contact us to delete it.<\/p>\n

<\/i> Author: Tess Boissonneault<\/p>\n","protected":false},"excerpt":{"rendered":"

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