Toward the Automation of the 3D Robotic Coreless Filament Winding Process for High-Performance Composite Materials With Multiple Reinforcement Levels

Abstract

Robotic coreless filament winding (CFW) of high-performance materials in 3D geometries presents a promising avenue for advancing lightweight and civil engineering. However, the unique challenges posed by CFW necessitate the development of novel path planning algorithms. Traditional slicing techniques, commonly used in regular 3D printing, are inadequate due to the complexities of filament winding processes and the utilization of materials with exceptional mechanical properties. In this article, we propose an innovative approach to automate 3D robotic CFW. The key focus of our work lies in overcoming the limitations of conventional algorithms and addressing the specific boundary conditions associated with diverse applications. Our method builds upon Hierholzer's algorithm that is then expanded to accommodate the intricate constraints of CFW. We achieve a comprehensive path planning framework capable of navigating complex 3D geometries while optimizing the utilization of high-performance materials. This approach allows efficient and precise CFW, preserving the excellent mechanical properties of the materials. Furthermore, the generated path is automatically converted into a robot program. The procedure to automatically convert a designed part to an executable robot program can be used in various sectors, including aerospace, automotive, and construction industry. This facilitates the utilization of high-performance fiber composites in lightweight engineering applications in the future.