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Enabling additive manufacturing to employ a wide range of novel, functional materials can be a major boost to this technology. However, making such materials printable requires painstaking trial-and-error by an expert operator, as they typically tend to exhibit peculiar rheological or hysteresis properties. Even in the case of successfully finding the process parameters, there is no guarantee of print-to-print consistency due to material differences between batches. These challenges make closed-loop feedback an attractive option where the process parameters are adjusted on-the-fly. There are several challenges for designing an efficient controller: the deposition parameters are complex and highly coupled, artifacts occur after long time horizons, simulating the deposition is computationally costly, and learning on hardware is intractable. In this work, we demonstrate the feasibility of learning a closed-loop control policy for additive manufacturing using reinforcement learning. We show that approximate, but efficient, numerical simulation is sufficient as long as it allows learning the behavioral patterns of deposition that translate to real-world experiences. In combination with reinforcement learning, our model can be used to discover control policies that outperform baseline controllers. Furthermore, the recovered policies have a minimal sim-to-real gap. We showcase this by applying our control policy in-vivo on a single-layer printer using low and high viscosity materials. 

In design, fabrication, and control problems, we are often faced with the task of synthesis, in which we must generate an object or configuration that satisfies a set of constraints while maximizing one or more objective functions. The synthesis problem is typically characterized by a physical process in which many different realizations may achieve the goal. This many-to-one map presents challenges to the supervised learning of feed-forward synthesis, as the set of viable designs may have a complex structure. In addition, the non-differentiable nature of many physical simulations prevents efficient direct optimization. We address both of these problems with a two-stage neural network architecture that we may consider to be an autoencoder. We first learn the decoder: a differentiable surrogate that approximates the many-to-one physical realization process. We then learn the encoder, which maps from goal to design, while using the fixed decoder to evaluate the quality of the realization. We evaluate the approach on two case studies: extruder path planning in additive manufacturing and constrained soft robot inverse kinematics. We compare our approach to direct optimization of the design using the learned surrogate, and to supervised learning of the synthesis problem. We find that our approach produces higher quality solutions than supervised learning, while being competitive in quality with direct optimization, at a greatly reduced computational cost. 

3D printing technology is a powerful tool for manufacturing complex shapes with high-quality textures. Gloss, next to color and shape, is one of the most salient visual aspects of an object. Unfortunately, printing a wide range of spatially-varying gloss properties using state-of-the-art 3D printers is challenging as it relies on geometrical modifications to achieve the desired appearance. A common post-processing step is to apply off-the-shelf varnishes that modify the final gloss. The main difficulty in automating this process lies in the physical properties of the varnishes which owe their appearance to a high concentration of large particles and as such, they cannot be easily deposited with current 3D color printers. As a result, fine-grained control of gloss properties using today's 3D printing technologies is limited in terms of both spatial resolution and the range of achievable gloss. We address the above limitations and propose new printing hardware based on piezo-actuated needle valves capable of jetting highly viscous varnishes. Based on the new hardware setup, we present the complete pipeline for controlling the gloss of a given 2.5D object, from printer calibration, through material selection, to the manufacturing of models with spatially-varying reflectance. Furthermore, we discuss the potential integration with current 3D printing technology. Apart from being a viable solution for 3D printing, our method offers an additional and essential benefit of separating color and gloss fabrication which makes the process more flexible and enables high-quality color and gloss reproduction.