Method for achieving digital design and manufacture of elements for manufacturing a three-dimensional object, installation for implementing same, and elements for manufacturing three-dimensional objects

Abstract

Disclosed is a method for achieving digital design and manufacture of elements for manufacturing a three-dimensional object obtained by superposing and / or placing side by side strata (2) the perimeters of which are particular shapes, consisting in carrying out the following operations: • in respect of the design: - selecting the object to be reproduced, selecting the reproduction scale, selecting the sheet material (3) in which said strata (2) will be formed, - digitizing the object, and carrying out digital decomposition via digital slicing, - identifying each of the elements (2) or strata, - determining the locations of an insert and of the hole (23) through which this insert will pass, which is designed based on partial sectioning of an element (2), - dividing the various elements (2) into groups (30), • in respect of the manufacture: - printing identification codes on sheets (3) of the selected material, - reproducing the groups (30) in the sheets (3) by cutting.

Description

[0001] [Process for digital design and manufacturing of elements for the manufacture of a three-dimensional object, the installation allowing its implementation, and elements for the manufacture of three-dimensional objects

[0002] The present invention relates to a method for digital design and manufacturing of elements for the manufacture of three-dimensional objects, as well as the installation allowing its implementation, and elements for the manufacture of three-dimensional objects. The invention relates, without limitation, to the recreational field of construction, and uses the known concept of superposition and / or juxtaposition of layers of particular perimeter shapes to reproduce the object to be manufactured.

[0003] We already know, in the aforementioned field of play, objects intended to be reconstituted by assembling pieces resulting from the cutting of a plate of material, and which constitute in a way a three-dimensional puzzle.

[0004] Some of these objects are made by assembling pieces, some perpendicular to others, by half-timbered joints, allowing volume to be given using little raw material, but with a result that is too "skeletal", which is not suitable for all the shapes that one wishes to reproduce.

[0005] Others are made by superimposing layers, with indexing and joining by an edge of each layer on a support, which limits the reproducible forms.

[0006] We thus know, from document IT 2021 0000 3545, a magnetic multi-layer assembly set of three-dimensional shape. For its design, it is proposed to digitize a chosen shape, to cut it into slices in order to create plates which, after superposition, make it possible to reproduce said original shape, the indexing of two adjacent plates being carried out by incorporating permanent magnets into the latter.

[0007] Finally, we know objects made up of the superposition of layers cut from a flat material, and assembled by being threaded onto at least one insert made of rigid material secured to a base, and arranged perpendicular to the planes of said layers. Preferably, more than one insert is used in order to obtain better indexing while avoiding risks of pivoting.

[0008] As for the design and manufacture of the elements intended for the production of these objects, this consists of breaking down the different elementary layers, cutting or pre-cutting them from sheets of material, and packaging them.

[0009] For objects comprising one or more inserts, the method comprises an additional step of drilling each of the elements for the passage of an insert.

[0010] Known manufacturing processes are very limited in the choice of objects to be designed, as well as the size of these objects.

[0011] The object of the present invention is to remedy this drawback by proposing a method of digital design and manufacturing of elements for the manufacture of a three-dimensional object obtained by the superposition and / or juxtaposition of layers of particular perimeter shapes of the object to be manufactured, going so far as to allow custom manufacturing at will.

[0012] The process of digital design and manufacturing of elements for the manufacture of a three-dimensional object obtained by the superposition and / or juxtaposition of layers of particular perimeter shapes of the object to be manufactured, is characterized in that it consists of carrying out the following operations:

[0013] • for design through a digital chain allowing: choice of the object to be reproduced, choice of the scale of reproduction of the object choice of the plate material in which said layers will be made, and recording of the thickness of said plate(s), digitization of said object to be manufactured or import of a file of suitable format, and digital decomposition of the latter and digital slicing into different complementary elementary layers, of thickness corresponding to that of said plate(s), choice of use of at least one guide insert, determination of the locations of said insert and of the passage hole of said insert for each of the elements, each constituting one of said layers, intended to be crossed by said insert, which is designed from the partial cutting of an element, and intended to be partially detached therefrom and to be straightened to be engaged in said hole of the adjacent element,and possibly in those of the following element(s), identification of each of the elements corresponding to a layer or stratum, distribution into at least one set of said different elements, optimization of said distribution according to the dimensions of said plate(s), their packaging, and their orientation,

[0014] • for manufacturing: printing of identification codes on at least one plate of material conforming to that chosen, reproduction of the set(s) on said plate(s) by cutting, including partial cutting of said insert(s), as well as of the associated passage(s)

[0015] The design and manufacturing method according to the invention makes it possible, from a virtually produced order, to design and manufacture an object to be reconstituted, while optimizing the quantity of material used.

[0016] The design and manufacturing method according to the invention may have numerous variants.

[0017] Thus, advantageously, during the panoply distribution optimization operation, the sizing of the plates is incorporated in accordance with the size of the packaging intended for the shipping packaging of said plates.

[0018] According to a variant, during the operation of optimizing the distribution in the panoply, knowing that we have an existing packaging of which we know the dimensions and storage capacity, we adjust the final dimensions of the object to be reconstituted and therefore those of the panoply(ies), so as to be able to package the panoply(ies) in said packaging.

[0019] According to another variant, during the panoply distribution optimization operation, the dimensions of each of the plates are simultaneously determined, as well as the characteristics and dimensions of the packaging intended for the shipping packaging of said plates, while during the manufacturing operation, said packaging is also produced.

[0020] According to an additional characteristic of the method according to the invention, during the operation of optimizing the distribution in a panoply, depending on the dimensions of the panels from which the plates must be cut, sub-assemblies are created, each grouping a certain number of plates, so as to allow optimized management of the material used, both at the level of said plates and at that of said panels.

[0021] It should be noted that the manufacturing operation may include the printing of assembly instructions.

[0022] According to an additional feature, several inserts are designed in the same element and / or in elements arranged at different levels.

[0023] According to another additional feature, inserts are designed which, although coming from different elements, pass through the same elements.

[0024] According to another additional feature, when choosing the material, its color is also determined and chosen.

[0025] According to another additional feature, the plates consist of corrugated cardboard.

[0026] In this regard, it should be noted that during the design operation, the orientation of the grooves is taken into account when forming the panoply. Indeed, this is important not only from the point of view of the aesthetic rendering, but also in the case of the creation of at least one insert, the two parallel cuts of which should preferably, for the purpose of rigidity, be parallel to said grooves.

[0027] According to another additional feature, a color deposit operation is digitally designed on the layers, according to an identification color code that can be used for the assembly operation, or to identify the final object on a visible layer by dedication or by a color logo.

[0028] According to another additional characteristic, a color deposit operation is digitally designed on the layers, at least on their peripheral edge on the portion intended not to be covered by the adjacent layer, and / or on the edge, then this color deposit is carried out.

[0029] The present invention also relates to an installation making it possible to implement the method of designing and manufacturing three-dimensional objects, it is characterized in that it comprises means for digitizing the object to be reproduced, computer means associated with one or more software programs for digital decomposition of said object by digital slicing into different complementary elementary layers, means for panoplying, means for transmitting data to printing means and cutting means.

[0030] The installation according to the invention is advantageously completed by robotic means of packaging in shipping packaging.

[0031] The present invention also relates to elements for the manufacture of a three-dimensional object designed by superposition and / or juxtaposition of strata of particular perimeter shapes, which elements constitute said strata, while at least one of said strata comprises a partially detachable part, capable of being folded to protrude from said stratum, while at least the adjacent stratum intended to be immediately superimposed, has an orifice intended to allow the narrow passage of said detachable part with a view to indexing the relative positioning of said strata and immobilizing one with respect to the other.

[0032] The advantages and characteristics of the method according to the invention will emerge more clearly from the description which follows and which refers to the attached drawing, which represents a non-limiting embodiment thereof.

[0033] In the attached drawing: Figure 1 represents a perspective view of a three-dimensional object produced with elements obtained by the design and manufacturing method according to the invention, Figure 2 represents a plan view of the elements obtained by the same method for producing the same object, Figure 3 represents a perspective view of a step in producing the same object, Figure 4 represents a perspective view of another step in producing the same object.

[0034] With reference to Figure 1, a three-dimensional object 1 can be seen, representing in this case, non-limitingly, a dog's head. It can be seen that this object 1 is obtained by the superposition in layers of elements 2 of particular perimeter contours. The elements 2 consist, in this non-limiting example, of parts of corrugated cardboard plates 3, previously cut while respecting the digital decomposition of the original object, the direction of the grooves 31, and its digital slicing into different complementary elementary layers, through a known process.

[0035] Figure 1 represents the object which can be constructed from the elements 2 designed and manufactured by means of the method according to the invention.

[0036] The method according to the invention makes it possible, from a chosen original object, to create and manufacture the elements 2 allowing it to be reconstituted. The method comprises a digitalization of the original object or the import of a three-dimensional CAD file, in a suitable format, concerning this object.

[0037] The aim being to offer, without limitation, a fun construction activity, the design and manufacturing method according to the invention includes, in addition to the manufacturing of the elements 2, their organization into sets and the optimized packaging of these in packaging ready for shipping and / or sale.

[0038] Thus, the method according to the invention allows several manufacturing options, including among others the choice of materials, the choice of colors and the choice of the reproduction scale.

[0039] With reference to figure 2, we can see a multiplicity of plates 3, each comprising a set 30, corresponding to the set of elements 2 making it possible to reconstitute the object 1. These elements 2 are pre-cut, so that they can be detached from the plates 3.

[0040] It will be noted that this figure 2 can also consist of the representation of the panoplies created during the design operation, upstream of the manufacturing operation. All the plates 3 are of the same dimensions, they are intended to be stacked then packaged in a packaging, not shown. The dimensions of the plates 3 are determined according to that of the packaging if it exists, or in an optimized manner in association with an operation of creation of the packaging.

[0041] The panoplying during the design is carried out in order to optimize the quantity of material used, and more particularly the number of plates 3 required.

[0042] It should be noted that it is possible to create sub-assemblies each grouping a certain number of 3 plates, allowing optimized management at two levels, that of the 3 plates and that of the panels from which the 3 plates come.

[0043] In addition to their particular peripheral contour, it can be seen that most of the elements 2 have internally total cutouts 20 or partial cutouts 21. The total cutouts 20 define, without limitation, slots 22 of a width at least equal, but preferably, to avoid play, equal to the thickness of the plate 3, while the partial cutouts 21 define tabs 23 of a width at most equal, but preferably, to avoid play, equal to the length of the slots 20, partially detachable from the plate 2 and straightenable by folding, in order to constitute a guide insert.

[0044] It will be noted that, preferably, the tabs 23 have at their base, that is to say at the level of the ends of the cutting lines, a transverse groove 24 intended to mark and facilitate folding to form the insert.

[0045] Also referring to figures 3 and , one can see in detail the mode of use of the slots 22 and the tabs 23.

[0046] In Figure 3, we can see a stack 4 of a certain number of elements 2, the last of which comprises two tabs 23 resulting from partial cuts 21, in the process of being straightened.

[0047] In Figure 4, it can be seen that an additional element 2 has been placed on the stack 4, that this element 2 has two total cutouts 20 creating two slots 22, in each of which is threaded a tab 23 coming from the element 2 which has just been covered. It will be understood that the tabs 23 make it possible on the one hand to constitute a framework perpendicular to the layers, and on the other hand to participate in the perfect positioning of the elements 2 relative to each other. Indeed, if identification codes of the elements 2 will have been initially printed on the plates 3 in order to know the stacking order, this is not sufficient for the correct indexing of the elements between them.

[0048] It will be noted in Figure 3 that the upper element 2 of the stack 4 also includes slots 22 in which tongues 23 from an element are engaged and flush

[0049] 2 of stack 4.

[0050] According to a variant not shown, it is possible to provide that elements 2 are crossed by tabs 23 coming from different elements 2, so as not to create a break in the reinforcement.

[0051] The positions of the cutouts 20 and 21 are of course determined during the decomposition and digital slicing. During this operation, if the material used consists of corrugated cardboard, the direction of the grooves 31 is taken into account for the orientation of the partial cutouts 21.

[0052] According to a variant, each of the elements is pierced with several holes, preferably at least two, intended to be passed through by rigid inserts, made of wood or other materials, delivered with the plates 3.

[0053] In its most common version, namely that the plates

[0054] 3 are made of corrugated cardboard, during the construction of the object 1 the plates 3 are joined by gluing. Therefore, the panoplies will be packaged with a glue container such as a tube, and it will be planned, during the design and manufacture of the panoplies 30, to reserve a space suitable for housing this container.

[0055] In a version including added inserts, one or more spaces will be provided in the same way to accommodate these inserts.

[0056] As for the cutting operation, it can be done in different ways.

[0057] Non-limitingly, a cutter cutting machine can be used, comprising a vibrating knife cutting head, which runs through the panoplies. It is also possible to use, in the case of large series for example, a machine equipped with cutting means allowing cutting in one press of an entire panoply.

Claims

Re vendicat ions |1) Method of digital design and manufacturing of elements for the manufacture of a three-dimensional object (1), obtained by the superposition and / or juxtaposition of layers (2) of particular perimeter shapes of the object (1) to be manufactured, characterized in that it consists of carrying out the following operations: • for design through a digital chain allowing: choice of the object (1) to be reproduced, choice of the scale of reproduction of the object (1), choice of the plate material (3) in which said layers (2) will be made, and recording of the thickness of said plates (3), digitization of said object (1) to be manufactured or import of a file of suitable format, and digital decomposition of the latter and digital slicing into different complementary elementary layers, of thickness corresponding to that of said plates (3), choice of use of at least one guide insert (23), determination of the locations of said insert (23) and of the hole (22) for passage of said insert (23) for each of the elements (2), each constituting one of said layers, intended to be crossed by said insert (23), which is designed from the partial cutting of an element (2), and intended to be partially detached therefrom and to be straightened to be engaged in said hole (22) of the adjacent element (2), and possibly in those of the following element(s) (2), identification of each of the elements (2) corresponding to a layer or stratum, distribution into panoplies (30) of said different elements (2), optimization of said distribution according to the dimensions of said plates (3), and their packaging, • for manufacturing: printing identification codes on plates (3) of material conforming to that chosen, reproduction of the panoplies (30) on said plates (3) by cutting, including the partial cutting of said insert(s) (23), as well as the associated passage(s) (22). 2) Design and manufacturing method according to claim 1, characterized in that during the operation of optimizing distribution in the panoply (30), knowing that there is an existing packaging of which the dimensions and storage capacity are known, the final dimensions of the object (1) to be reconstituted and therefore those of the panoply or panoplies (30) are adjusted, so as to be able to package the panoply or panoplies (30) in said packaging. 3) Design and manufacturing method according to claim 1, characterized in that during the operation of optimizing the distribution in the array (30), the sizing of the plates (3) is incorporated in accordance with the size of the packaging intended for the shipping packaging of said plates (3). 4) Design and manufacturing method according to claim 3, characterized in that during the panoply distribution optimization operation, (30) the dimensions of each of the plates (3) are simultaneously determined, as well as the characteristics and dimensions of the packaging intended for the shipping packaging of said plates (3), while during the manufacturing operation, said packaging is also produced. 5) Design and manufacturing method according to any one of claims 1 to 4, characterized in that during the operation of optimizing the distribution in a panoply (30), depending on the dimensions of the panels from which the plates (3) must be cut, sub-assemblies are created, each grouping together a certain number of plates (3), so as to allow optimized management of the material used, both at the level of said plates (3) and at that of said panels. 6) Design and manufacturing method according to any one of claims 1 to 5, characterized in that several inserts (23) are designed in the same element (2) and / or in elements (2) arranged at different levels. 7) Design and manufacturing method according to claim 6, characterized in that inserts (23) are designed which, although originating from different elements (2), pass through the same elements (2). 8) Design and manufacturing method according to any one of claims 1 to 7, characterized in that when choosing the material, the color of the material is also determined and chosen. 9) Design and manufacturing method according to any one of claims 1 to 8, characterized in that the plates (3) consist of corrugated cardboard. 10) Design and manufacturing method according to claim 9, characterized in that during the design operation, the orientation of the grooves (31) of the corrugated cardboard is taken into account when forming the array (30). 11) Design and manufacturing method according to any one of claims 1 to 10, characterized in that a color deposit operation on the elements (2) is digitally designed, according to an identification color code usable for the assembly operation. 12) Design and manufacturing method according to any one of claims 1 to 11, characterized in that a color deposition operation is digitally designed on the elements (2), at least on their peripheral edge on the portion intended not to be covered by the adjacent element (2), and / or on the edge, then this color deposition is carried out. 13) Installation for implementing the method of digital design and manufacturing of three-dimensional objects according to any one of claims 1 to 12, characterized in that it comprises means for digitizing the object to be reproduced, computer means associated with one or more software programs for digital decomposition of said object by digital slicing into different complementary elementary layers, means for panoplying, means for transmitting data to printing means and cutting means. 14) Installation according to claim 13, characterized in that it also comprises robotic means for packaging in shipping packaging. 15) Elements for the manufacture of a three-dimensional object designed by superposition and / or juxtaposition of strata of particular perimeter shapes, and resulting from the digital design and manufacturing process according to any one of claims 1 to 12, characterized in that they constitute said strata (2), and in that at least one of said strata (2) comprises a partially detachable part (23), capable of being folded to protrude from said stratum (2), while at least the adjacent stratum (2) intended to be immediately superimposed, has an orifice (22) intended to allow the narrow passage of said detachable part (23) for the purpose of indexing the relative positioning of said strata (2) and immobilizing one with respect to the other. |