Parameters of a set of tools are stored on a storage device. The tools are part of a manufacturing assembly usable for removing one or more support structures from a part. The support structures are formed with the part to facilitate additive manufacturing of the part. A near-net shape is modeled which includes the part combined with the support structures. A process plan is developed that includes subtractive manufacturing operations by the manufacturing assembly that remove the support structures. The process plan repeatedly updates the near-net shape as each one of the support structures is incrementally removed.

A three-dimensional laser machine includes a machine head, a controller for positioning the machine head and controlling an orientation of a nozzle, and a sensor for detecting a distance between a workpiece and the nozzle. The controller is capable of performing a profile control of correcting the position of the machine head based on the detected distance. When the machine head has reached a predetermined position part way through an approach process of moving the machine head from an approach start position to a machining start position while controlling the pose of the nozzle, the controller performs the profile control to move the machine head to the machining start position.

Systems and methods for providing real-time modification of cutting process programs using feedback from one or more sensors which measure one or more operational parameters of a cutting process and/or cutting apparatus. The sensor readings may be used to provide real-time modification of a motion program after such motion program has been provided to a motion controller. Examples of such operational parameters may include waterjet pump supply pressure, the abrasive mass flow rate, the force of the waterjet on the target piece, etc. The systems and methods discussed herein also utilize a cutting algorithm or program to calculate actual cut quality based on one or more sensor inputs, and to generate warnings or system shut-downs accordingly. The systems and methods discussed herein also utilize inspection devices to inspect coupons or first articles, and use the inspection data to autonomously modify motion programs and/or cutting process models without user intervention.

Systems and methods for providing real-time modification of cutting process programs using feedback from one or more sensors which measure one or more operational parameters of a cutting process and/or cutting apparatus. The sensor readings may be used to provide real-time modification of a motion program after such motion program has been provided to a motion controller. Examples of such operational parameters may include waterjet pump supply pressure, the abrasive mass flow rate, the force of the waterjet on the target piece, etc. The systems and methods discussed herein also utilize a cutting algorithm or program to calculate actual cut quality based on one or more sensor inputs, and to generate warnings or system shut-downs accordingly. The systems and methods discussed herein also utilize inspection devices to inspect coupons or first articles, and use the inspection data to autonomously modify motion programs and/or cutting process models without user intervention.

Systems and methods for providing real-time modification of cutting process programs using feedback from one or more sensors which measure one or more operational parameters of a cutting process and/or cutting apparatus. The sensor readings may be used to provide real-time modification of a motion program after such motion program has been provided to a motion controller. Examples of such operational parameters may include waterjet pump supply pressure, the abrasive mass flow rate, the force of the waterjet on the target piece, etc. The systems and methods discussed herein also utilize a cutting algorithm or program to calculate actual cut quality based on one or more sensor inputs, and to generate warnings or system shut-downs accordingly. The systems and methods discussed herein also utilize inspection devices to inspect coupons or first articles, and use the inspection data to autonomously modify motion programs and/or cutting process models without user intervention.

A system and a method allow for the removal of excess material from a dental appliance. The system includes at least one 5-axis computer numerical control (CNC) machine and at least one administrative computing system. The administrative computing system is used to determine the trim line for the dental appliance. The administrative computing system is also used to determine a tool path for an automated tool that is an integrated part of the 5-axis CNC machine. The tool path is then relayed from the administrative computing system to the 5-axis CNC machine. The 5-axis CNC machine is used to machine off the excess material from the dental appliance along the trim line, while the automated tool follows the tool path.

Computer based methods, systems, and techniques for planning and generating machining paths for a tool that manufactures a three dimensional object having beveled or “compound” contours from a workpiece. A computer aided design (CAD)/computer aided manufacturing (CAM) system creates intermediate machining path surfaces that extend based on a CAD solid model representing the geometry of the object to be manufactured. The intermediate machining path surfaces extend to a shape that simulates a cutting beam (e.g., a waterjet, a laser beam, etc.) of the tool. For a flat workpiece, the machining path surfaces may extend from a top surface of the workpiece, which is a tool beam entrance surface, to a bottom surface of the workpiece, which is a tool beam exit surface. An operator is able to visualize the cuts to be made and the actual finished object geometry, without requiring the creation of multiple CAD solid models.

Algorithmic reasoning about a cutting tool assembly's space of feasible configurations can be effectively harnessed to construct a sequence of motions that guarantees a collision-free path for the tool assembly to remove each support structure in the sequence. A greedy algorithm models the motion of the cutting tool assembly through the free-spaces around the intermediate shapes of the part as the free-spaces iteratively reduce in size to the near-net shape to determine feasible points of contact for the cutting tool assembly. Each support beam is evaluated for a contact feature along the boundary of the near-net shape that constitutes a feasible point of contact. If a support beam has at least one feasible configuration at each point, the support beam is deemed ‘accessible’ and a collection of tool assembly configurations that are guaranteed to be non-colliding but which can access all points of contact of each accessible support beam can be generated.

A three-dimensional laser machine includes a machine head, a controller for positioning the machine head and controlling an orientation of a nozzle, and a sensor for detecting a distance between a workpiece and the nozzle. The controller is capable of performing a profile control of correcting the position of the machine head based on the detected distance. When the machine head has reached a predetermined position part way through an approach process of moving the machine head from an approach start position to a machining start position while controlling the pose of the nozzle, the controller performs the profile control to move the machine head to the machining start position.

A laser device, including multiple laser modules, includes a plurality of drive power units that drive the laser modules, a plurality of output detection units that detect laser outputs from the laser modules, and output detected values as first output signals, a coupled output detection unit that detects a total laser output after coupling of a plurality of the laser outputs, and outputs a detected value as a second output signal, a computing unit that sets multiple output correction factors for correspondingly controlling the laser modules using the plurality of first output signals and the second output signal, and a control unit that controls the plurality of drive power units using the multiple output correction factors. The multiple output correction factors are each set to allow the total laser output to be maintained at a constant value.