Robots, Lasers and Supersonic Jets: The Tool Path Planning Project

Oral Presentation | Peter King

Date & Time: Thursday June 25 2020, 14:10


Peter King, Alejandro Vargas-Uscategui, Hans Lohr, Clement Chu, Nazmul Alam.

CSIRO Manufacturing, Gate 5, Normanby Road, Clayton, VIC 3168, Australia.

Metal additive manufacturing (AM) using robots allows large components to be built at high deposition rates in a fully automated production environment. Two teams at CSIRO’s Lab22 have been developing laser metal cladding and cold spray for coating or for repair for various applications. These and other processes can be extended into the domain of large rebuilding and freestanding component manufacture. They have a number of advantages over powder bed and other flat layer-by-layer 3d printing approaches. Firstly, they are not constrained to build objects as a stack of flat X-Y planes, but can add material to different facets each with a unique build direction. Greater anisotropy in physical properties can be achieved, and there is less reliance on support material in models with large overhangs. The layers themselves need not be flat but can be cylindrical, spherical or replicate the facet geometry.  Multiple deposition processes can be incorporated and machining or surface finishing can take place during the build.

This talk outlines current progress in development of software that that converts a CAD file into a series of robot instructions. The software is currently being tested to manufacture components in different configurations including dual, coordinated robots. It is envisaged that if used online during a build, coupled with optical monitoring of the part geometry, toolpaths may be adjusted on-the-fly to correct for small deviations in shape.

Presentation Video

Presenting Author

Peter King

Team Leader
CSIRO – Manufacturing

Peter is a Materials Engineer who specialises in metal additive manufacturing, cold spray and surface treatments. After completing a Bachelor’s Degree in Materials Science and Engineering at Monash University, and PhD at Deakin University, Peter joined CSIRO as a postdoctoral fellow in 2006. At CSIRO he has been mainly involved in the development of new cold spray applications and techniques. Peter is actively engaged with industry, and has built long-term relationships with key partners for the cold spray lab. He has published extensively on mechanisms of particle bonding and properties. Peter currently leads the Deposition and Additive Structures team at CSIRO.