Robust Higher-Order Spatial Iterative Learning Control for Additive Manufacturing Systems

In this article, a higher-order spatial iterative learning control (HO-SILC) scheme is proposed, targeting heightmap tracking for a class of 3-D structures fabricated by repetitive addition of material in a layer-by-layer fashion using additive manufacturing (AM) technology. AM processes are innately iteration-varying, resulting in large model uncertainties due to iteration-varying system parameters and surface variations. HO-SILC has been shown to be useful in repetitive systems with model uncertainties by improving system performance with respect to convergence speed and robustness. In this article, HO-SILC is used to iteratively construct a feedforward control signal to improve part quality in multilayered AM constructs. The system dynamics are approximated by discrete 2-D spatial convolution kernels that incorporate in-layer and layer-to-layer variations. The proposed HO-SILC framework incorporates data available from previously printed devices, as well as multiple previously printed layers, to enhance the overall performance. The condition for robust monotonic convergence (RMC) of the iteration-varying HO-SILC algorithm is based on the Lyapunov stability criteria. Simulation results of an AM process termed electrohydrodynamic jet (e-jet) printing demonstrate that a well-designed HO-SILC framework is effective and can improve the performance by 60%. In addition, HO-SILC is robust to iteration-varying model uncertainties, especially at higher layers where iteration-varying surface variations are more pronounced.