An apparatus and method for calibrating an automated wire bending machine is provided that includes a camera system comprising a camera and a lens configured with a focal plane fixedly positioned relative to a bending surface provided on the automated wire bending machine. The disclosed apparatus and method further includes a processor device configured to interpret images captured by the camera system. The apparatus and method measures an actual angle formed in a wire while a bent portion of the wire is substantially within the focal plane of the camera system, and a memory device stores values generated during a calibration sequence of the automated wire bending machine. The values correspond to the actual angle and a target angle provided for the calibrating of the automated wire bending machine.

Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design of physical structures using generative design processes, where the 3D models of the physical structures are produced so as to facilitate manufacturing of the physical structures using 2.5-axis subtractive manufacturing systems and techniques, include: obtaining a design space for an object to be manufactured, design criteria, and load case(s); iteratively modifying a generatively designed 3D shape of the modeled object, including generating 2D profile representations (corresponding to discrete layers) of an updated version of the 3D shape, extruding the 2D profile representations along the milling direction, and forming a next version of the 3D shape of the modeled object from a combination of the 3D representations produced by the extruding; and providing the generatively designed 3D shape of the modeled object for use in manufacturing the physical structure using a 2.5-axis subtractive manufacturing process.

The invention relates to a device, system and method of automated manufacture comprising: delivering a workpiece with a delivery device; receiving the workpiece with a receiving device, the delivering of the workpiece and the receiving of the workpiece being electronically synchronized; processing the workpiece with a processing tool while the workpiece is on the receiving device; transferring the workpiece to a completion device, the ejection of the workpiece and the transferring of the workpiece being electronically synchronized. In particular the workpiece may comprise: a platform with mounts supporting a first component in a selected orientation; and a locating surface, the method comprising: engaging and disengaging the locating surface of the workpiece with releasable connectors on the delivery device, on the receiving device and on the completion device.

An apparatus and associated method for operating a machine tool having a selectively movable turret and a tool mounted to the turret. A cover is configured to be removably secured to the turret and sized so that the cover encloses the tool when the cover is secured to the turret. Turret control logic includes computer instructions stored in a computer memory and executable by a computer processor to limit movement of the turret when the cover is secured to the turret.

A system and method for fabricating a custom face mask. The system includes a factory client, wherein the factory client includes a computing device configured to receive, at a factory server and at least a user device, an image datum comprising a plurality of data of a face of a user. The computing device is further configured to map, as a function of a first machine-learning model, at least a facial landmark to a three-dimensional (3D) mesh of the image datum, map, as a function of a second machine-learning mode, a path to the 3D mesh including a boundary of a custom face mask configured for use on a user's face, generate a model file of a mold, instruct a manufacturing tool, and instruct a manufacturing device to thermoform the plastic component of the mold.

Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design of physical structures using generative design processes, where the 3D models of the physical structures are produced so as to facilitate manufacturing of the physical structures using 2.5-axis subtractive manufacturing systems and techniques, include: obtaining a design space for an object to be manufactured, design criteria, and load case(s); iteratively modifying a generatively designed 3D shape of the modeled object, including generating 2D profile representations (corresponding to discrete layers) of an updated version of the 3D shape, extruding the 2D profile representations along the milling direction, and forming a next version of the 3D shape of the modeled object from a combination of the 3D representations produced by the extruding; and providing the generatively designed 3D shape of the modeled object for use in manufacturing the physical structure using a 2.5-axis subtractive manufacturing process.

A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.

Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design of physical structures using generative design processes, where the 3D models of the physical structures are produced so as to facilitate manufacturing of the physical structures using 2.5-axis subtractive manufacturing systems and techniques, include: obtaining a design space for an object to be manufactured, design criteria, and load case(s); iteratively modifying a generatively designed 3D shape of the modeled object, including generating 2D profile representations (corresponding to discrete layers) of an updated version of the 3D shape, extruding the 2D profile representations along the milling direction, and forming a next version of the 3D shape of the modeled object from a combination of the 3D representations produced by the extruding; and providing the generatively designed 3D shape of the modeled object for use in manufacturing the physical structure using a 2.5-axis subtractive manufacturing process.

A method of manufacturing a composite structure includes accessing design data for the composite structure that is manufactured according to a process including forming a layup of plies of fibers using a machine tool. The method includes applying the design data to an ANN classifier to classify a localized inconsistency of a type of inconsistency on the composite structure, the localized inconsistency spatially referenced to a location on the composite structure. The method includes performing a root cause analysis to identify one or more of process parameters as a potential cause of the type of inconsistency, and modifying one or more of the geometric model, the layup design, or values of the one or more of the process parameters to address the potential cause.

A method of forming a part using additive manufacturing may include receiving, at a computer numeric controlled (CNC) machine, a computer aided design (CAD) model of the part. The method may further include dividing the CAD model into plurality of sections. The method may further include slicing each of the plurality of sections into a plurality of layers. Each section may include a distinct set of print parameters. The method may further include depositing a flowable material onto a worktable according the set of print parameters for each section of the of the plurality of sections to manufacture the part.