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Abstract We present NoodlePrint, a generalized computational framework for maximally concurrent layer-wise cooperative 3D printing (C3DP) of arbitrary part geometries with multiple robots. NoodlePrint is inspired by a recently discovered set of helically interlocked space-filling shapes called VoroNoodles. Leveraging this unique geometric relationship, we introduce an algorithmic pipeline for generating helically interlocked cellular segmentation of arbitrary parts followed by layer-wise cell sequencing and path planning for cooperative 3D printing. Furthermore, we introduce a novel concurrence measure that quantifies the amount of printing parallelization across multiple robots. Consequently, we integrate this measure to optimize the location and orientation of a part for maximally parallel printing. We systematically study the relationship between the helix parameters (i.e., cellular interlocking), the cell size, the amount of concurrent printing, and the total printing time. Our study revealed that both concurrence and time to print primarily depend on the cell size, thereby allowing the determination of interlocking independent of time to print. To demonstrate the generality of our approach with respect to part geometry and the number of robots, we implemented two cooperative 3D printing systems with two and three printing robots and printed a variety of part geometries. Through comparative bending and tensile tests, we show that helically interlocked part segmentation is robust to gaps between segments. 

An approach for modeling topologically interlocked building blocks that can be assembled in a water‐tight manner (space filling) to design a variety of spatial structures is introduced. This approach takes inspiration from recent methods utilizing Voronoi tessellation of spatial domains using symmetrically arranged Voronoi sites. Attention is focused on building blocks that result from helical stacking of planar 2‐honeycombs (i.e., tessellations of the plane with a single prototile) generated through a combination of wallpaper symmetries and Voronoi tessellation. This unique combination gives rise to structures that are both space‐filling (due to Voronoi tessellation) and interlocking (due to helical trajectories). Algorithms are developed to generate two different varieties of helical building blocks, namely, corrugated and smooth. These varieties result naturally from the method of discretization and shape generation and lead to distinct interlocking behavior. In order to study these varieties, finite‐element analyses (FEA) are conducted on different tiles parametrized by 1) the polygonal unit cell determined by the wallpaper symmetry and 2) the parameters of the helical line generating the Voronoi tessellation. Analyses reveal that the new design of the geometry of the building blocks enables strong variation of the engagement force between the blocks.