Adaptive Slicing Algorithm and Path Planning for Additive Manufacturing of Aerospace Parts

Zekai Tian

doi:10.54254/2755-2721/2025.GL27145

Applied and Computational EngineeringOpen access

Adaptive Slicing Algorithm and Path Planning for Additive Manufacturing of Aerospace Parts

Research Article

Open Access

Adaptive Slicing Algorithm and Path Planning for Additive Manufacturing of Aerospace Parts

Zekai Tian ^1*

¹ Dalian Maritime University

^*Corresponding author: tianzekai998839@dlmu.edu.cn

Published on 24 September 2025

ACE Vol.186

ISSN (Print): 2755-273X

ISSN (Online): 2755-2721

ISBN (Print): 978-1-80590-383-3

ISBN (Online): 978-1-80590-384-0

Download Cover

Abstract

In the aerospace field, the requirements for high precision, lightweight and geometric complexity of complex structural parts are becoming increasingly stringent. Additive manufacturing,especially directed energy deposition(DED) technology has become the core means to achieve this goal. However, traditional additive manufacturing processes suffer from geometric deviations (such as the staircase effect) and low efficiency due to fixed slice layer thickness and unreasonable path planning. Moreover, the existing adaptive slicing algorithms and path planning technologies have not been deeply coordinated with advanced processes such as DED. This paper systematically reviews the research progress of adaptive slicing algorithms based on curvature, slope and features, and path planning technologies such as LSPB, MTT and robot instruction systems. It focuses on analyzing the application of the mechanism of matching path trajectories through dynamic layer thickness adjustment, combined with real-time monitoring of the molten pool image and synchronous control of robot motion in the manufacturing of aerospace parts. It also presents the achievements of high-precision manufacturing in aero-engine turbine blades and titanium alloy components with thin walls and holes. Finally, the existing challenges such as real-time optimization barriers, the compatibility problems of DED processes, and the contradiction between efficiency and precision under complex models, are put forward.

Keywords:

Adaptive Slicing, Path Planning, Directed Energy Deposition, Aerospace Manufacturing, Additive Manufacturing

View PDF

References

[1]. Sukhorukov, S., Ovsyannikov, A., & Lepekhina, S. (2024). A set of technological equipment for a robotic 3D printing system using DED technology. In 2024 International Conference on Industrial Engineering, Applications and Manufacturing(ICIEAM)(pp.812–817).IEEE.

[2]. V. Sala, A. Vandone, M. Banfi, S. Baraldo, F. Mazzucato and A. Valente, "Online 3D Geometry Reconstruction for Direct Energy Deposition Based on Melt Pool Images, " 2023 IEEE International Workshop on Metrology for Industry 4.0 & IoT (MetroInd4.0& IoT), Brescia, Italy, 2023, pp. 96-101

[3]. Jin, Y., He, Y., Fu, G., Zhang, A., & Du, J. (2017). A non-retraction path planning approach for extrusion-based additive manufacturing. Robotics and Computer-Integrated Manufacturing, 48, 132–144.

[4]. Sanaei, N., & Fatemi, A. (2021). Defects in additive manufactured metals and their effect on fatigue performance: A state-of-the-art review. Progress in Materials Science, 117, 100724

[5]. Ma, W., But, W. C., & He, P. (2004). NURBS - based adaptive slicing for efficient rapid prototyping. Computer - Aided Design, 36(13), 1309 - 1325.

[6]. B. Thompson and H. -S. Yoon, "Efficient Path Planning Algorithm for Additive Manufacturing Systems, " in IEEE Transactions on Components, Packaging and Manufacturing Technology, vol. 4, no. 9, pp. 1555-1563, Sept. 2014, .

[7]. B. Hu, G. Jin and L. Sun, "A Novel Adaptive Slicing Method for Additive Manufacturing, " 2018 IEEE 22nd International Conference on Computer Supported Cooperative Work in Design ((CSCWD)), Nanjing, China, 2018, pp. 218-223,

[8]. Uhlmann, E., Kersting, R., Klein, T. B., Cruz, M. F., & Borille, A. V. (2015). Additive manufacturing of titanium alloy for aircraft components. Procedia CIRP, 35, 55-60.

[9]. Kumar, L.J., Krishnadas Nair, C.G. (2017). Current Trends of Additive Manufacturing in the Aerospace Industry. In: Wimpenny, D., Pandey, P., Kumar, L. (eds) Advances in 3D Printing & Additive Manufacturing Technologies. Springer, Singapore.

[10]. S. Sukhorukov and N. Shusharin, "Command System for a Robotic 3D Printing Complex Using DED Technology, " 2024 International Russian Smart Industry Conference (SmartIndustryCon), Sochi, Russian Federation, 2024, pp. 184-189,

References

[4]. Sanaei, N., & Fatemi, A. (2021). Defects in additive manufactured metals and their effect on fatigue performance: A state-of-the-art review. Progress in Materials Science, 117, 100724

[5]. Ma, W., But, W. C., & He, P. (2004). NURBS - based adaptive slicing for efficient rapid prototyping. Computer - Aided Design, 36(13), 1309 - 1325.

[8]. Uhlmann, E., Kersting, R., Klein, T. B., Cruz, M. F., & Borille, A. V. (2015). Additive manufacturing of titanium alloy for aircraft components. Procedia CIRP, 35, 55-60.

Cite this article

Tian,Z. (2025). Adaptive Slicing Algorithm and Path Planning for Additive Manufacturing of Aerospace Parts. Applied and Computational Engineering,186,78-86.

Data availability

The datasets used and/or analyzed during the current study will be available from the authors upon reasonable request.

About volume

Volume title: Proceedings of CONF-FMCE 2025 Symposium: Semantic Communication for Media Compression and Transmission

ISBN: 978-1-80590-383-3(Print) / 978-1-80590-384-0(Online)

Editor: Anil Fernando

Conference website: https://2025.conffmce.org/glasgow.html

Conference date: 24 October 2025

Series: Applied and Computational Engineering

Volume number: Vol.186

ISSN: 2755-2721(Print) / 2755-273X(Online)

© 2024 by the author(s). Licensee EWA Publishing, Oxford, UK. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license. Authors who publish this series agree to the following terms:

1. Authors retain copyright and grant the series right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgment of the work's authorship and initial publication in this series.

2. Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the series's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgment of its initial publication in this series.

3. Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) prior to and during the submission process, as it can lead to productive exchanges, as well as earlier and greater citation of published work (See Open access policy for details).