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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

An End-to-End Framework for Verifying and Validating Manufacturing Design Integrity

Cyber attacks on networked automated manufacturing systems can severely impact part quality. In fact, malicious modifications may be introduced at any point during the manufacturing lifecycle. Therefore, it is vital to verify and validate that manufactured parts conform to their designs. This chapter describes a formal, end-to-end framework that verifies and validates the design integrity of manufactured parts by considering all potential points of alteration during precision manufacturing processes. The framework prevents unauthorized changes to computer-aided designs, verifies the correctness of translations from CAD models to G-code, maintains the integrity of G-code transferred to manufacturing machines, verifies the runtime execution of G-code and part geometry, and considers the contexts of manufacturing machine operations and how manufactured parts could be altered.

Jablonski, Matthew [Cybersecurity Manufacturing In↗
DOE OSTI2025

Slicing Solutions for Wire Arc Additive Manufacturing

Both commercial and research applications of wire arc additive manufacturing (WAAM) have seen considerable growth in the additive manufacturing of metallic components. However, there remains a clear lack of a unified paradigm for toolpath generation when slicing parts for WAAM deposition. Existing toolpath generation options typically lack the appropriate features to account for all complexities of the WAAM process. This manuscript explores the key slicing challenges specific to toolpaths for WAAM geometry and pairs each consideration with multiple solutions to mitigate most negative effects on completed components. These challenges must be addressed to minimize voids, prevent bead collapse, and ensure deposited components accurately approximate the desired geometry. Slicing considerations are grouped into four general categories: geometric, process, thermal, and productivity. Geometric considerations are addressed with overhang compensation, corner-sharpening, and toolpath-smoothing features. Process considerations are addressed with start point configuration and controls for the bead lengths and end points. Thermal and productivity considerations are addressed with island optimization, multi-material printing, and connected insets. Finally, tools for the post-processing of generated G-code are explored. Overall, these solutions represent a critical set of slicing features used to improve generated toolpaths and the quality of the components deposited with those toolpaths.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Fundamental Path Optimization Strategies for Extrusion-based Additive Manufacturing

Extrusion-based additive manufacturing processes begin with a software program, called a slicer, that generates layer geometry and fits toolpaths to each layer to define where material is to be extruded or deposited. Before the toolpaths are output as g-code for the additive manufacturing system to execute, the toolpaths should be optimized. Many complex optimization approaches using graph theory, Chinese postman problem, and other complex mathematical models exist, but these approaches are rarely used in daily printing operations and are not available through common slicing programs such as Cura and PrusaSlicer. Instead, path planning and optimization typically revolves around simpler, fully automated approaches such as inside out and next closest. This paper will explore the fundamental optimization strategies for toolpath planning and document a new implementation, available via open-source slicing software, that allows for greater control of the path planning process.

Roschli, Alex [ORNL] (ORCID:0000000213084632)↗
DOE OSTI2025

Exact signed distance fields using parallel Fast Sweeping Method

Signed distance fields are often used in multiphysics simulations to track material interfaces. We present a simple methodology based on the fast sweeping method to generate the exact signed distance from triangular meshes and linear paths on Cartesian grids. The methodology propagates the closest primitive to the boundary to the rest of the domain following the characteristics. A local upwind criterion is used to decide between the new and existing closest primitive at each grid point while capturing the correct sign of the global function. The methodology has optimal computational complexity and runs efficiently in distributed-memory architectures. We include 2D and 3D test cases along with a resolution study up to 0.512 trillion zones and 1,000 computer cores. The solution strategy can also be applied to other types of meshes or collections of primitives.

97 MATHEMATICS AND COMPUTING↗