Organizations: 1. State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou, 310027, China · 2. Engineering Research Center for Design Engineering and Digital Twin of Zhejiang Province, Zhejiang University, Hangzhou, 310027, China · 3. Zhejiang Changxing Heliang Intelligent Equipment Co., Ltd., Huzhou 313000, China
Abstract
Design for manufacturing plays a critical role in advanced aeroengine development, where complex components necessitate careful consideration of manufacturability. However, current practices in pipe routing remain largely decoupled from down-stream manufacturing, leading to labor-intensive, trial-and-error iterations to achieve manufacturable designs. To address this problem, this study proposes the Frenet-based pipe routing optimization (FPRO) framework, a manufacturability knowledge-integrated reinforcement learning approach for free-form pipe design in aeroengines. FPRO formulates the routing problem as a boundary value problem in the Frenet frame. In this framework, the pipe path is represented by curvature and torsion profiles, which are generated using cubic Hermite interpolation. To integrate design and manufacturing, domain-specific manufacturing knowledge is embedded as constraints on the permissible ranges of curvature and torsion. The path optimization is performed using the proximal policy optimization algorithm with stochastic exploration and a stage-guided reward mechanism. A unified mapping formulation then translates the optimized path into motion trajectories for the bending die, enabling direct fabrication on a six-axis free-bending machine. Experimental results demonstrate that FPRO consistently generates collision-free, manufacturable paths with smoother geometric profiles compared to Cartesian-based methods. It also achieves faster convergence and superior performance in terminal alignment, path length, obstacle avoidance, and manufacturability compared to state-of-the-art reinforcement learning baselines. Real-world validation confirms the close geometric correspondence between the manufactured pipe and its digital design, validating the practical feasibility of FPRO.
Graph-based machine learning has emerged as a promising approach for manufacturability analysis by learning directly from CAD models represented as Boundary Representations (B-reps), exploiting both surface geometry and topological connectivity. However, purely geometric representations often lack the process-specific semantics required for accurate manufacturability prediction: many manufacturing factors, such as surface roles or bend intent, are not explicitly encoded in shape alone and are difficult for data-driven models to infer reliably. We propose a hybrid approach that addresses this challenge by enriching B-rep attributed adjacency graphs with manufacturing features recognized through a rule-based module. Applied to sheet metal bending, recognized features, such as bend characteristics, flange lengths, and surface roles are integrated as node attributes, concentrating the learning signal on process-relevant geometric patterns. Experiments on both a large-scale synthetic manufacturability benchmark and a real-world industrial dataset with measured bending times, one of the first such validations on genuine production data, demonstrate that combining domain knowledge with graph-based learning improves prediction accuracy across both tasks. The results demonstrate that hybrid modeling offers a feasible and effective path toward deployable tools for manufacturability assessment and effort estimation in industrial CAD environments.
Matteo Ballegeer, Toon Van Camp, Willem Jaspers +6
Manufacturing complex soft pneumatic actuators remains challenging because geometric fidelity, compliance, structural integrity, and airtightness must be achieved simultaneously. This study presents a manufacturing-focused evaluation of several fabrication routes for complex pneumatic structures, including heat-shrink forming, silicone casting, powder- and liquid-based additive manufacturing, and fused deposition modeling (FDM). The processes were assessed through process screening, baseline fabrication, failure analysis, and process improvement to distinguish inherent process limitations from correctable manufacturing defects. Heat-shrink forming was limited by geometric conformity, casting by mold accessibility and bonded interfaces, powder-based methods by residual material trapped within enclosed passages, and digital light processing by the material properties and post-processing requirements of the investigated system. FDM provided the most adaptable route because its dominant defects could be progressively reduced through process optimization. The results further showed that airtightness depends not only on nominal wall thickness but also on extrusion-path architecture, while support-free geometry is important when access for internal post-processing is limited. These findings establish a practical design-for-manufacturing approach in which process selection is guided by the compatibility between actuator architecture and manufacturing constraints. The proposed approach provides practical guidance for developing complex, flexible, and airtight soft pneumatic actuators for soft robotic applications
Nowadays, the creation of a process flow diagram (PFD) and its subsequent transformation into a piping and instrumentation diagram (P&ID) is predominantly performed manually. Applying artificial intelligence in the task could potentially lead not only to process automation and time savings, but also to financial gains by exploring numerous diagram's topology options and reducing manual labor. This research presents P&ID Pilot - a practical end-to-end AI pipeline capable of handling flowsheet developing for both stages. The first stage focuses on PFD synthesis, whereas the second is directed toward modifying the generated PFD into P&ID. After comparing four different methods, the hybrid approach combining genetic algorithms (GA) and large language models (LLM) is shown to generate the optimal valid PFD topology, achieving the lowest loss value among all the methods, while satisfying the required outlet flow parameters without engineering-rule violations. For the second stage, the proposed LLM-based agent successfully transforms the generated PFD into a source-grounded P&ID by producing validated, executable modifications through a restricted engineering software development kit, achieving 100% execution success while maintaining compliance with domain-specific rules and reference graph structures. This unified pipeline - coupling GA/LLM-driven synthesis with an LLM-based transformation agent - offers a feasible path toward end-to-end process design automation by producing validated, deployable outputs and substantially reduces manual engineering effort.