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A 3D printing nesting algorithm with dynamic collision constraints.

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Title: A 3D printing nesting algorithm with dynamic collision constraints.
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]
Copyright of International Journal of Production Research is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: A 3D printing nesting algorithm with dynamic collision constraints.
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  Data: <searchLink fieldCode="AR" term="%22Rocha%2C+Pedro%22">Rocha, Pedro</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Ramos%2C+António+G%2E%22">Ramos, António G.</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Silva%2C+Elsa%22">Silva, Elsa</searchLink><relatesTo>2</relatesTo> (AUTHOR)<i> elsa@dps.uminho.pt</i>
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Production+Research%22">International Journal of Production Research</searchLink>. Jun2026, Vol. 64 Issue 11, p4419-4439. 21p.
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  Data: <searchLink fieldCode="DE" term="%22Fused+deposition+modeling%22">Fused deposition modeling</searchLink><br /><searchLink fieldCode="DE" term="%22Packing+problem+%28Mathematics%29%22">Packing problem (Mathematics)</searchLink><br /><searchLink fieldCode="DE" term="%22Three-dimensional+printing%22">Three-dimensional printing</searchLink><br /><searchLink fieldCode="DE" term="%22Metaheuristic+algorithms%22">Metaheuristic algorithms</searchLink><br /><searchLink fieldCode="DE" term="%22Rapid+prototyping%22">Rapid prototyping</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: 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]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Production Research is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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      – Type: doi
        Value: 10.1080/00207543.2025.2604312
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      – Code: eng
        Text: English
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        PageCount: 21
        StartPage: 4419
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      – SubjectFull: Fused deposition modeling
        Type: general
      – SubjectFull: Packing problem (Mathematics)
        Type: general
      – SubjectFull: Three-dimensional printing
        Type: general
      – SubjectFull: Metaheuristic algorithms
        Type: general
      – SubjectFull: Rapid prototyping
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      – TitleFull: A 3D printing nesting algorithm with dynamic collision constraints.
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            NameFull: Rocha, Pedro
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            NameFull: Ramos, António G.
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            NameFull: Silva, Elsa
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            – D: 01
              M: 06
              Text: Jun2026
              Type: published
              Y: 2026
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            – TitleFull: International Journal of Production Research
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