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An additive manufacturing (AM) process often produces a {\it near-net} shapethat closely conforms to the intended design to be manufactured. It sometimescontains additional support structure (also called scaffolding), which has tobe removed in post-processing. We describe an approach to automaticallygenerate process plans for support removal using a multi-axis machininginstrument. The goal is to fracture the contact regions between each supportcomponent and the part, and to do it in the most cost-effective order whileavoiding collisions with evolving near-net shape, including the remainingsupport components. A recursive algorithm identifies a maximal collection ofsupport components whose connection regions to the part are accessible as wellas the orientations at which they can be removed at a given round. For everysuch region, the accessible orientations appear as a 'fiber' in thecollision-free space of the evolving near-net shape and the tool assembly. Toorder the removal of accessible supports, the algorithm constructs a searchgraph whose edges are weighted by the Riemannian distance between the fibers.The least expensive process plan is obtained by solving a traveling salesmanproblem (TSP) over the search graph. The sequence of configurations obtained bysolving TSP is used as the input to a motion planner that finds collision freepaths to visit all accessible features. The resulting part without the supportstructure can then be finished using traditional machining to produce theintended design. The effectiveness of the method is demonstrated throughbenchmark examples in 3D.

Automatic Support Removal for Additive Manufacturing Post Processing