A 3D printing nesting algorithm with dynamic collision constraints.
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| Title: | A 3D printing nesting algorithm with dynamic collision constraints. |
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| Authors: | Rocha, Pedro1 (AUTHOR), Ramos, António G.1 (AUTHOR), Silva, Elsa2 (AUTHOR) elsa@dps.uminho.pt |
| Source: | International Journal of Production Research. Jun2026, Vol. 64 Issue 11, p4419-4439. 21p. |
| Subjects: | Fused deposition modeling, Packing problem (Mathematics), Three-dimensional printing, Metaheuristic algorithms, Rapid prototyping |
| Abstract: | Additive Layer Manufacturing, particularly Fused Deposition Modelling, faces significant batch loss risks during production. The traditional Concurrent Printing Mode produces all parts simultaneously (layer-by-layer, bottom-to-top), efficiently using printing space but risking complete batch failure if problems occur. In contrast, Sequential Printing Mode produces one part at a time, reducing the risk of total batch loss but utilising printing space less efficiently. In this work, we propose an algorithm that, given a set of parts, performs the nesting of the parts for Concurrent Printing Mode, and for the first time, for the Sequential Printing Mode. A no-fit polygon based approach is used to handle geometry between pairs of parts by using multiple horizontal 2D layer projections of 3D parts, to ensure non-overlapping constraints and prevent machine-part collisions. A Greedy Randomized Adaptive Search Procedure is proposed, tested and benchmarked against a commercial software, using a new set of real-world instances. The approach shows the ability to find high-quality solutions. The approach significantly reduces the number of batches, minimises waste, reduces manufacturing time, and promotes parts quality. [ABSTRACT FROM AUTHOR] |
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| Database: | Engineering Source |
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| Abstract: | Additive Layer Manufacturing, particularly Fused Deposition Modelling, faces significant batch loss risks during production. The traditional Concurrent Printing Mode produces all parts simultaneously (layer-by-layer, bottom-to-top), efficiently using printing space but risking complete batch failure if problems occur. In contrast, Sequential Printing Mode produces one part at a time, reducing the risk of total batch loss but utilising printing space less efficiently. In this work, we propose an algorithm that, given a set of parts, performs the nesting of the parts for Concurrent Printing Mode, and for the first time, for the Sequential Printing Mode. A no-fit polygon based approach is used to handle geometry between pairs of parts by using multiple horizontal 2D layer projections of 3D parts, to ensure non-overlapping constraints and prevent machine-part collisions. A Greedy Randomized Adaptive Search Procedure is proposed, tested and benchmarked against a commercial software, using a new set of real-world instances. The approach shows the ability to find high-quality solutions. The approach significantly reduces the number of batches, minimises waste, reduces manufacturing time, and promotes parts quality. [ABSTRACT FROM AUTHOR] |
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| ISSN: | 00207543 |
| DOI: | 10.1080/00207543.2025.2604312 |
