Task-Driven 3D Printability Assistance via Geometry- and Knowledge-Grounded LLM Reasoning

We use fused deposition modeling (FDM) 3D printing as a case study of how manufacturing robots can use imperfect AI. In FDM, print configuration strongly affects output quality. Yet, novice users typically rely on default configurations, trial-and-error, or direct recommendations from generic AI models (e.g., ChatGPT). These strategies can produce complete prints, but they do not reliably meet specific objectives. We present a modular approach that treats an LLM as a source of tuning expertise. We embed this source of expertise within a Bayesian optimization loop. An approximate evaluator scores each candidate print configuration and returns structured diagnostics, which the LLM uses to propose natural-language adjustments that are compiled into machine-actionable guidance for optimization. On 100 Thingi10k parts, our LLM-guided loop achieves the best configuration on 78% objects with 0% likely-to-fail cases, while direct AI model recommendations are rarely best and exhibit 15% likely-to-fail cases. These results suggest that LLMs provide more value as constrained decision modules in optimization loops than as end-to-end oracles for print configuration selection. We expect this result to extend to broader LLM-based robot programming.

Additive manufacturing (AM) continues to transform modern manufacturing by enabling flexible, on-demand production of complex geometries across diverse industries. Fused filament fabrication (FFF) has extended AM to laboratories, classrooms, and small production environments, but this accessibility shifts process-planning responsibility to users who may lack manufacturing expertise. A syntactically valid slicer profile can still encode thermally or geometrically harmful settings, and subtle G-code edits can alter extrusion, cooling, or adhesion before a print begins. Pre-print G-code screening catches accidental or adversarial machine-program errors before material or machine time is wasted. This paper proposes LLM-ADAM as a generalizable LLM framework for pre-print anomaly detection in AM. The framework decomposes the task into three roles: Extractor-LLM maps a G-code file to a structured process-parameter schema; Reference-LLM converts printer and material documentation into aligned operating ranges; and Judge-LLM interprets a deterministic deviation table and G-code evidence to decide whether a part is non-defective or belongs to an anomaly class. Printers, materials, and LLM backbones are interchangeable test conditions, not fixed assumptions. We evaluate the framework on an N=200 FFF G-code corpus spanning two desktop printer families, two materials, and five classes including non-defective, under-extrusion, over-extrusion, warping, and stringing. The best framework configuration reaches 87.5% accuracy, compared with 59.5% for the strongest engineered single-LLM baseline. The results show that structured decomposition, rather than backbone strength alone, is the dominant source of improvement, with defect classes identified at or near ceiling for leading configurations while residual errors concentrate on conservative false alarms for non-defective samples.

LLM-based agents are increasingly capable of generating complex 3D structures, with the potential to reshape how objects are designed and realized in the physical world. Yet, producing elegant geometry is fundamentally different from producing objects that can be built and perform their intended functions. Existing evaluations largely focus on geometric quality while overlooking physical realizability. We introduce LMBuild, a benchmark for evaluating LLM agents on generating buildable and functional structures. LMBuild represents generated objects as assembled structures comprising part decompositions, joints, materials, and sequences. To support reproducible evaluation, we provide a unified framework consisting of: (1) an interactive environment in which agents can use tools to retrieve, create, and place components to construct objects; (2) a curated benchmark that repurposes established CAD datasets and augments them with knowledge from Wikipedia; and (3) a evaluation framework covering structural soundness, functional affordance, design quality, and physical realization. Evaluations across 30 systems reveal several intriguing findings: (a) Soundness and alignment are no longer the primary bottlenecks for frontier closed-source models, while functional affordance and physical operability remain substantially more challenging; (b) stronger models more effectively create new components, whereas weaker models tend to rely on retrieval; and (c) providing functional specifications substantially improves part completeness, kinematics, and physical operability. These results show that generating real-world structures requires deeper reasoning about functional affordances, mechanics, and designing and creating novel components. We expect LMBuild to provide a foundation for measuring progress and incentivizing research toward agents that generate buildable and functional structures.