Conventional subtractive manufacturing inevitably involves material loss during geometric realization, while additive manufacturing still suffers from limitations in surface quality, process continuity, and productivity when fabricating complex geometries. To address these challenges, this paper proposes a volume-consistent kneading-based forming method for plastic materials, enabling continuous and controllable three-dimensional deformation under mass conservation. An integrated kneading-based manufacturing system is developed, in which geometry-aware kneading command generation, layer-wise kneading execution, and in-process point-cloud scanning are tightly coupled to form a closed-loop workflow of scanning, forming, and feedback compensation. Target geometries are analyzed through layer-wise point-cloud processing and classified into enveloping and non-enveloping types. Accordingly, an Envelope Shaping First strategy and a Similar Gradient Method are adopted to ensure stable material flow and continuous deformation. An RMSE-based compensation scheme is further introduced to correct systematic geometric deviations induced by elastic rebound and material redistribution. Experimental validation on five representative geometries demonstrates high geometric fidelity, with material utilization consistently exceeding 98%. The results indicate that kneading-based forming provides a promising alternative manufacturing paradigm for low-waste, customizable production.

翻译：传统减材制造在几何实现过程中不可避免地伴随材料损耗，而增材制造在成形复杂几何结构时仍受限于表面质量、工艺连续性与生产效率。为应对这些挑战，本文提出一种面向塑性材料的体积守恒捏合成形方法，在质量守恒条件下实现连续可控的三维变形。研究开发了集成化捏合制造系统，其中几何感知的捏合指令生成、分层捏合执行与在线点云扫描紧密耦合，形成扫描-成形-反馈补偿的闭环工作流。通过分层点云处理对目标几何体进行分析，将其分类为包络型与非包络型结构。据此采用"包络成形优先"策略与相似梯度法，确保稳定的材料流动与连续变形。进一步引入基于均方根误差的补偿方案，以修正由弹性回弹与材料重分布引起的系统几何偏差。通过对五种典型几何体的实验验证，本方法展现出高几何保真度，材料利用率持续超过98%。结果表明，捏合成形技术为低废料、可定制的生产提供了一种具有前景的替代制造范式。