Robotic manufacturing of near-net-shape components utilizing stereo imaging and reconfigurable tooling

Abstract

A process is described to acquire geometrical data of the target object and to utilize it to rapidly create a near-net-shape component with flexible tooling system. The topological data acquisition of the object is made possible using a robot-assisted stereo-imaging technique. Stereo-image data is translated into CAD data, and subsequently the geometric data constitutes the basis for the path planning for the tooling process. A novel, rapidly reconfigurable tooling system and tool forming technology is employed by which a six-axis robotic arm is used to shape a discretized vacuum surface. Pre-heated thermoplastic sheets are formed over the shaped vacuum tool to generate near-net-shape parts. The parts may be trimmed and used as the final component or they may be used as molds for subsequent fabrication of composite components. We demonstrate the process first in the context of an abstract reference part. One of the many applications envisaged using this process is the manufacture of custom-made braces, masks, and guards for use in healthcare products. A patient intervention can have their features acquired using stereo imaging and have corrective measures incorporated into the product prior to manufacturing. Since the geometrical data acquisition process does not require physical contact, the method can be used for patients having epidermal or skeletal damage. Furthermore, employing the rapidly reconfigurable tooling technology will significantly reduce the process cycle time and permit complete customization, benefiting the patient with a quicker and more effective administration of medical assistance. The healthcare context of the proposed integrated process is demonstrated with the manufacture of an orthopedic component with personalized fit.