A Disturbance-Aware Multi-Objective Planning Framework for Concurrent Robotic Wire-Based DED-LB/M and Milling

Hybrid robotic manufacturing systems integrating additive and subtractive processes enable fabrication of complex, high-value components but are typically executed sequentially, resulting in long cycle times. Concurrent execution of Directed Energy Deposition (DED) and milling promises productivity gains but introduces coupled thermal, mechanical and spatial interactions that challenge conventional process planning. This work addresses the methodological problem of planning milling operations in the presence of an ongoing DED process. The concurrent planning task is formulated as a mixed-integer, nonlinear, multi-objective optimisation problem capturing sequencing and orientation decisions, cutting parameters and enabling temporal coupling to the deposition trajectory. A hierarchical, surrogate-assisted optimisation framework is proposed, combining unified decision-variable encoding, deterministic decoding and staged feasibility enforcement to ensure robotic executability. Disturbance mechanisms such as thermal interaction, particulate interference and pose-dependent dynamic compatibility are incorporated as modular objective abstractions, enabling systematic trade-offs between machining productivity and preservation of deposition process integrity. The proposed framework is demonstrated on a representative case study, enabling analysis of the interaction between spatial sequencing, temporal feasibility and disturbance-aware optimisation. The case study provides a controlled instantiation and illustrates its application to concurrent additive–subtractive planning under explicitly modelled temporal and disturbance constraints.