The functionality and aesthetic of 3D-printed components can be compromised if visible defects appear on their external surfaces. To overcome this issue, CNC machines were traditionally adopted for milling machining. More recently, industrial robots have been demonstrated to be a valid alternative. This study presents a robotic workstation developed for contouring machining 3D thermoplastic components printed using the material extrusion technology. The workstation adopts a collaborative robot with a novel, custom-designed, and low-cost end-effector made of a powered contouring tool integrated with three load cells for measuring the cutting forces along three perpendicular directions. The tool path planning is defined by a proposed and validated procedure. By a vision algorithm and a touch-stop operation, the 3D CAD model-based tool path is adapted to the current position and orientation of the workpiece. The experimental activity for determining the optimal set of contouring machining parameters (rotational speed, cut depth, and feed rate) and for measuring cutting forces confirms the feasibility of adopting the cobot-based solution for this application and suggests potential improvements for future works.

Interpolation of a robot joint trajectory is realized using trigonometric splines. This original application has several advantages over existing methods (e.g. those using algebraic splines). For example, the computational expense is lower, more constraints can be imposed on the trajectory, obstacle avoidance can be implemented in real time, and smoother trajectories are obtained. Some of the spline parameters can be chosen to minimize an objective function (e.g. minimum jerk or minimum energy). If jerk is minimized, the optimization has a closed form solution. This paper introduces a trajectory interpolation algorithm, discusses a method for path optimization, and includes examples.

Often inspection and maintenance work involve a large number of highly dangerous manual operations, especially within industrial fields such as shipbuilding and construction. This paper deals with the autonomous climbing robot which uses the “caterpillar” concept to climb in complex 3D metallic-based structures. During its motion the robot generates in real-time the path and grasp planning in order to ensure stable self-support to avoid the environment obstacles, and to optimise the robot consumption during the inspection. The control and monitoring of the robot is achieved through an advanced Graphical User Interface to allow an effective and user friendly operation of the robot. The experiments confirm its advantages in executing the inspection operations.