| Abstract Scope |
Scrapping end-of-life components leads to material loss, while complete material recovery through reprocessing requires substantial energy. This paper proposes a framework for repurposing retired components into new functional geometries using hybrid additive and subtractive manufacturing, with the objective of minimizing material wastage and energy usage during transformation. Rigid-body alignment between the source component and target geometry is optimized using Covariance Matrix Adaptation Evolution Strategy over the full three-dimensional rotation space, while translation is determined analytically for each rotation via fast Fourier transform cross-correlation. The aligned geometries are then compared to identify shared material to be retained, missing volume to be deposited, and excess volume to be removed, which are evaluated through a weighted cost function. Feasible manufacturing operations are sequentially planned using Monte Carlo Tree Search under evolving tool-accessibility constraints with a five-term cost model for processing, support, accessibility, reconfiguration, and tool change. |