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On Experimental Emulation of Printability and Fleet Aware Generic Mesh Decomposition for Enabling Aerial 3D Printing
Luleå University of Technology, Department of Computer Science, Electrical and Space Engineering, Signals and Systems.ORCID iD: 0009-0004-8990-2066
Luleå University of Technology, Department of Computer Science, Electrical and Space Engineering, Signals and Systems.ORCID iD: 0000-0003-3557-6782
Luleå University of Technology, Department of Computer Science, Electrical and Space Engineering, Signals and Systems.ORCID iD: 0000-0003-0126-1897
2024 (English)In: 2024 IEEE International Conference on Robotics and Automation (ICRA), IEEE, 2024, p. 10080-10086Conference paper, Published paper (Refereed)
Abstract [en]

This article introduces an experimental emulation of a novel chunk-based flexible multi-DoF aerial 3D printing framework. The experimental demonstration of the overall autonomy focuses on precise motion planning and task allocation for a UAV, traversing through a series of planned space-filling paths involved in the aerial 3D printing process without physically depositing the overlaying material. The flexible multi-DoF aerial 3D printing is a newly developed framework and has the potential to strategically distribute the envisioned 3D model to be printed into small, manageable chunks suitable for distributed 3D printing. Moreover, by harnessing the dexterous flexibility due to the 6 DoF motion of UAV, the framework enables the provision of integrating the overall autonomy stack, potentially opening up an entirely new frontier in additive manufacturing. However, it’s essential to note that the feasibility of this pioneering concept is still in its very early stage of development, which yet needs to be experimentally verified. Towards this direction, experimental emulation serves as the crucial stepping stone, providing a pseudo mockup scenario by virtual material deposition, helping to identify technological gaps from simulation to reality. Experimental emulation results, supported by critical analysis and discussion, lay the foundation for addressing the technological and research challenges to significantly push the boundaries of the state-of-the-art 3D printing mechanism. - Full mission video available at https://youtu.be/gfZuYCA8jAw

Place, publisher, year, edition, pages
IEEE, 2024. p. 10080-10086
National Category
Robotics and automation
Research subject
Robotics and Artificial Intelligence
Identifiers
URN: urn:nbn:se:ltu:diva-109776DOI: 10.1109/ICRA57147.2024.10610806ISI: 001369728001040Scopus ID: 2-s2.0-85202436609OAI: oai:DiVA.org:ltu-109776DiVA, id: diva2:1895940
Conference
2024 IEEE International Conference on Robotics and Automation (ICRA), Yokohama, Japan, May 13-17, 2024
Note

ISBN for host publication: 979-8-3503-8457-4; 

Available from: 2024-09-09 Created: 2024-09-09 Last updated: 2025-10-21Bibliographically approved
In thesis
1. Towards Autonomous Collaborative Aerial 3D Printing
Open this publication in new window or tab >>Towards Autonomous Collaborative Aerial 3D Printing
2025 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Additive Manufacturing (AM) is transforming construction by enabling autonomous, large-scale building. Most existing research focuses on gantry systems and ground robots, which face limitations such as heavy infrastructure, heavy machinery, and restricted workspace. This thesis explores Aerial Additive Manufacturing (AAM) using unmanned aerial Vehicles (UAVs) as mobile builders that deposit material layer by layer. Despite its potential, this approach introduces a distinct set of challenges, including constrained payload capacities, the need for precise manipulation, and the complexity of coordinating multi-agent systems. To address these, a chunk-based aerial 3D printing framework is proposed, covering planning, execution, and coordinated UAV control. A key contribution is a mesh decomposition algorithm that splits structures into printable chunks, enabling balanced task distribution and parallel execution while respecting structural constraints. An offset-free Model Predictive Control (MPC) strategy enhances aerial printing by compensating for ground effects, UAV dynamic asymmetries, and varying payloads, improving both stability and precision. The framework is validated in simulation using Gazebo and in a mockup experiment with a real UAV performing virtual deposition. For full validation, a custom hexacopter with a foam extrusion system demonstrates controlled, precise material deposition. The framework is also extended to support simultaneous multi-UAV deployment, where coordination is guided by structural dependencies among the chunks. Task allocation is performed dynamically, prioritizing critical components to prevent bottlenecks and ensure a smooth workflow, while also accounting for the probabilistic likelihood of conflicts between assignments. Finally, conflict resolution is achieved by minimizing the extent of velocity adjustments required to maintain safe, collision-free operation. This allows UAVs to operate concurrently with minimal delays, thereby improving overall efficiency and productivity in aerial construction. In conclusion, this thesis advances AAM further by introducing a chunk-based planning and coordination framework and laying the foundation for the realization of collaborative aerial autonomous construction.

Place, publisher, year, edition, pages
Luleå University of Technology, 2025
Series
Licentiate thesis / Luleå University of Technology, ISSN 1402-1757
Keywords
Aerial 3D Printing, Aerial Additive Manufacturing, Aerial Robotics, Mission Planning, Mesh Decomposition, Aerial Task Assingment, Conflict Resolution
National Category
Robotics and automation
Research subject
Robotics and Artificial Intelligence
Identifiers
urn:nbn:se:ltu:diva-112607 (URN)978-91-8048-837-2 (ISBN)978-91-8048-838-9 (ISBN)
Presentation
2025-06-16, A1545, Luleå University of Technology, Luleå, 08:30 (English)
Opponent
Supervisors
Available from: 2025-05-08 Created: 2025-05-08 Last updated: 2025-10-21Bibliographically approved

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Stamatopoulos, Marios-NektariosBanerjee, AvijitNikolakopoulos, George

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