Method and system for generating computer object data for additive manufacturing

Abstract

A method of generating computer object data for additive manufacturing includes displaying a graphical user interface (GUI); loading image data describing the two-dimensional image selected by the GUI; and defining a plurality of discrete tile elements based on the tile pattern selected by the GUI, each tile element associated with a different portion of the image data. The method further includes displaying a three-dimensional image on the GUI, the three-dimensional image including a plurality of discrete raised elements respectively raised from tiled elements, where each raised element has a three-dimensional shape selected by a set of relief selection controls, and wherein the at least one segment of each raised element has at least one intensity level according to a respective portion of the image data. The method also includes generating computer object data describing the raised elements.

Description

[0001] By incorporating via reference

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 471,538, filed June 7, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] Some embodiments of the present invention relate to additive manufacturing, and more specifically, but not exclusively, to a method and system for generating computer object data for additive manufacturing. Background Technology

[0004] Additive manufacturing (AM) is a technology that directly creates shaped structures based on computer data through additive manufacturing steps. The basic operation of any additive manufacturing system involves slicing a three-dimensional computer model into thin cross-sections, converting the results into two-dimensional positional data, and inputting the data into a control device that manufactures the three-dimensional structure in a layered manner.

[0005] Additive manufacturing involves a variety of different manufacturing methods, including three-dimensional (3D) printing, such as 3D inkjet printing. 3D inkjet printing is achieved by depositing build material layer by layer using inkjet printing. Therefore, build material is dispensed from a dispensing head with a set of nozzles and deposited in layers on a support structure. These layers are then leveled by a leveling device and cured or hardened.

[0006] There are various 3D printing technologies, all of which are disclosed by the same assignee in multiple patents, such as U.S. Patent Nos. 6,259,979, 6,569,373, 6,658,314, 6,850,334, 6,863,859, 7,183,335, 7,209,797, 7,225,045, 7,300,619, 7,500,846, 9,031,680, and 9,227,365, U.S. Publication No. 20060054039, and International Publications Nos. WO2016 / 009426 and WO2022 / 024114, the contents of which are incorporated herein by reference in their entirety. For example, international publication WO2022 / 024114 describes a system for 3D printing that includes a nozzle array for dispensing build material, a work tray, a fixture for securing fabric to the work tray, and a computerized controller for operating the nozzle array to dispense build material onto the secured fabric. An imaging system can be configured to image the fabric placed on the work tray, and the image data received from the imaging system can be processed to identify patterns on the fabric, wherein the nozzles dispense build material at positions selected relative to the identified features. Summary of the Invention

[0007] According to one aspect of some embodiments of the present invention, a method for generating computer object data for additive manufacturing is provided. The method includes: displaying a graphical user interface (GUI) including an image selection control group, a tiling selection control group, and an embossing selection control group; loading image data describing a two-dimensional image selected by the image selection control group; and defining a plurality of discrete tiling elements based on a tiling pattern selected by the tiling control group, each tiling element being associated with a different portion of the image data. The method further includes displaying a three-dimensional image on the GUI, the three-dimensional image including a plurality of discrete raised elements that protrude from the tiling elements of the tiling pattern, wherein each raised element has a three-dimensional shape selected by the embossing selection control group, and wherein at least one segment of each raised element has at least one intensity level according to a corresponding portion of the image data. The method further includes generating computer object data describing the raised elements and storing the computer object data in a computer storage device.

[0008] According to some embodiments of the present invention, the method includes: identifying background regions and non-background regions in an image, wherein discrete tiling elements only tile the non-background regions.

[0009] According to some embodiments of the present invention, the tile selection control group is configured to allow users to independently select the shape of the tiled elements and the spacing between the tiled elements.

[0010] According to some embodiments of the present invention, the tile selection control group is configured to allow users to independently select the size of the tiled elements.

[0011] According to some embodiments of the present invention, the tile selection control group is configured to allow users to select different sizes for different tiled elements.

[0012] According to some embodiments of the present invention, the tile selection control group is configured to allow users to select different spacings between different pairs of tiled elements.

[0013] According to some embodiments of the present invention, the emboss selection control group is configured to allow a user to select at least one of the following: (i) different heights of different embossed elements, (ii) different spacing between different pairs of embossed elements, and (iii) different cross-sectional dimensions of different embossed elements.

[0014] According to some embodiments of the present invention, the emboss selection control group is configured to automatically select at least one of the following: (i) different heights of different raised elements, (ii) different spacing between different pairs of raised elements, and (iii) different cross-sectional dimensions of different raised elements.

[0015] According to some embodiments of the present invention, the emboss selection control group is configured to select the height of the raised element based on the corresponding portion of the image data.

[0016] According to some embodiments of the present invention, the method includes: loading image data describing an additional image, wherein for at least one raised element, the intensity levels of different segments of the raised element are based on image data of different images.

[0017] According to some embodiments of the present invention, a graphical user interface (GUI) includes a height map control group configured to generate or import height maps, wherein an emboss selection control group is configured to select the height of a raised element based on the height map.

[0018] According to some embodiments of the present invention, a graphical user interface (GUI) includes a density map control group configured to generate or import density maps, wherein an emboss selection control group is configured to select the density of raised elements based on the density map.

[0019] According to some embodiments of the present invention, a graphical user interface (GUI) includes a dimension map control group configured to generate or import dimension maps, wherein an emboss selection control group is configured to select the cross-sectional dimensions of raised elements based on the dimension map.

[0020] According to some embodiments of the present invention, the graphical user interface (GUI) includes a lensing control group that allows the user to select a lensing scheme, wherein the shape, color, and transparency level of the raised element are selected based on the lensing scheme.

[0021] According to some embodiments of the present invention, the graphical user interface (GUI) includes a lensing control group that allows the user to instruct the GUI to automatically select a lensing scheme, wherein the shape, color, and transparency level of the raised element are selected based on the lensing scheme.

[0022] According to some embodiments of the present invention, the method includes segmenting computer object data into a plurality of slices, each slice being defined by a plurality of voxels, and storing these slices in a computer storage device. According to one aspect of some embodiments of the present invention, an additive manufacturing method is provided. The method includes performing the methods described above, and optionally and preferably performing the methods further detailed below; loading slices generated by the method from a computer storage device; for each voxel of each slice, allocating build material according to at least one strength level of a corresponding protrusion element containing the voxel; and transmitting the plurality of slices and corresponding build material allocations to a controller of an additive manufacturing system for additive manufacturing of a plurality of layers respectively corresponding to the plurality of slices.

[0023] According to one aspect of some embodiments of the present invention, a computer software product is provided. The computer software product includes a computer-readable medium storing program instructions that, when read by a data processor, cause the data processor to perform the described method, and the method may optionally and preferably be described in further detail below.

[0024] According to one aspect of some embodiments of the present invention, an additive manufacturing method is provided. The method includes performing the above-described method, and optionally and preferably performing the method further detailed below; loading computer object data from a computer storage device; slicing the computer object data into a plurality of slices, each slice being defined by a plurality of voxels; for each voxel of each slice, allocating build material according to at least one intensity level of a corresponding protrusion element containing the voxel; and transmitting the plurality of slices and corresponding build material allocation information to a controller of an additive manufacturing system to additively manufacture a plurality of layers respectively corresponding to the plurality of slices.

[0025] According to some embodiments of the invention, the method includes mounting a fabric on a tray of an additive manufacturing system so that the system forms multiple layers on the fabric.

[0026] According to one aspect of some embodiments of the present invention, a system for generating computer object data for additive manufacturing is provided. The system includes a display device, a computer, and a computer storage device, wherein the computer includes a processor configured to perform the methods described above, and optionally and preferably to perform the methods described in further detail below.

[0027] Unless otherwise defined, all technical and / or scientific terms used herein have the meanings commonly understood by one of ordinary skill in the art to which this invention pertains. While similar or equivalent methods and materials may be used in carrying out or testing embodiments of the invention, exemplary methods and / or materials are described below. In case of conflict, the patent specification (including definitions) shall prevail. Furthermore, materials, methods, and examples are for illustrative purposes only and are not intended to constitute necessary limitations.

[0028] The implementation of the methods and / or systems of the embodiments of the present invention may involve performing or completing selected tasks manually, automatically, or in combination thereof. Furthermore, according to the actual instruments and equipment of the methods and / or systems of the embodiments of the present invention, certain selected tasks may be implemented by hardware, software, or firmware, or by using an operating system and a combination thereof.

[0029] For example, according to embodiments of the present invention, hardware for performing a selected task can be implemented in the form of a chip or circuit. As software, the selected task according to embodiments of the present invention can be implemented in the form of multiple software instructions executed by a computer using any suitable operating system. In exemplary embodiments of the present invention, one or more tasks according to exemplary embodiments of the methods and / or systems described herein are performed by a data processor, such as a computing platform for executing multiple instructions. Optionally, the data processor includes volatile memory for storing instructions and / or data and / or non-volatile memory for storing instructions and / or data, such as a magnetic hard disk and / or removable media. Optionally, network connectivity is also provided. Optionally, a display and / or user input device, such as a keyboard or mouse, are also provided. Attached Figure Description

[0030] This document describes certain embodiments of the invention by way of example only and with reference to the accompanying drawings. A detailed description will now be given with reference to the accompanying drawings. It should be emphasized that the details shown are merely illustrative and intended to illustrate embodiments of the invention. In this regard, the description taken in conjunction with the accompanying drawings will enable those skilled in the art to understand how to practice embodiments of the invention.

[0031] In the attached diagram:

[0032] Figure 1A -D is a schematic diagram of an additive manufacturing system according to some embodiments of the present invention;

[0033] Figure 2A -C is a schematic diagram of a printhead according to some embodiments of the present invention;

[0034] Figure 3A and 3B This is a schematic diagram of coordinate transformation according to some embodiments of the present invention;

[0035] Figure 4A -F is a schematic diagram of a graphical user interface (GUI) according to some embodiments of the present invention, which is suitable for performing a method of converting a two-dimensional image into computer object data;

[0036] Figure 5A -F is a schematic diagram of a raised element that can be used in the method according to some embodiments of the present invention;

[0037] Figure 6 This is a flowchart illustrating a method for generating computer object data for additive manufacturing according to some embodiments of the present invention;

[0038] Figure 7A and 7B This is a schematic diagram of raised elements characterized by different levels of refinement; and

[0039] Figure 8A and 8B This is a schematic diagram of raised elements characterized by different severity values. Detailed Implementation

[0040] In some embodiments, the present invention relates to additive manufacturing, and more specifically, but not exclusively, to a method and system for generating computer object data for additive manufacturing.

[0041] Before explaining at least one embodiment of the present invention in detail, it should be understood that the application of the present invention is not necessarily limited to the details of the construction and arrangement of the components and / or methods described in the following description and / or drawings and / or examples. The present invention can have other embodiments, or can be practiced or performed in various ways.

[0042] The method and system of this embodiment are based on computer object data and manufacture three-dimensional objects in a layered manner by forming multiple layers in a configuration pattern corresponding to the shape of the object. The formation of layers can be optionally and preferably achieved by printing, and more preferably by inkjet printing. The computer object data can be any known format, including but not limited to Standard Triangulation Language (STL) or Stereolithography Profile (SLC) format, OBJ file format (OBJ), 3D Manufacturing Format (3MF), Virtual Reality Modeling Language (VRML), Additive Manufacturing File (AMF) format, Graphics Exchange Format (DXF), Polygon File Format (PLY), and any other format suitable for computer-aided design (CAD).

[0043] Computer object data can be a data structure containing multiple graphical elements (e.g., polygonal meshes, non-uniform rational basis spline curves, etc.). Typically, these graphical elements are converted into voxel meshes to define the shape of the object; for example, multiple slices are formed using a slicing procedure, each slice containing multiple voxels, describing the layers of the 3D object.

[0044] Since voxel meshes and multiple graphical elements describe the same object, the term "computer object data" used in this paper refers to both voxel meshes and multiple graphical elements. Therefore, when computer object data is associated with a voxel mesh, each element of the computer object data is a voxel; when computer object data is associated with graphical elements, each element of the computer object data is a graphical element, such as a polygon, spline, etc.

[0045] As used in this article, the term "object" refers to a complete three-dimensional object or a part thereof.

[0046] Each layer can be formed by an additive manufacturing (AM) apparatus that scans and patterns a two-dimensional surface. During the scanning process, the apparatus accesses multiple target locations on the two-dimensional layer or surface and determines for each target location or group of target locations whether to fill that location or group of target locations with a build material formulation, and what type of build material formulation to deliver. This decision is made based on a computer image of the surface.

[0047] In a preferred embodiment of the invention, additive manufacturing (AM) includes three-dimensional printing, more preferably three-dimensional inkjet printing. In these embodiments, build material is dispensed from a printhead having one or more nozzle arrays to deposit build material layer by layer onto a support structure. The additive manufacturing apparatus thus dispenses build material to target locations to be occupied, leaving other target locations empty. The apparatus typically includes multiple nozzle arrays, each configurable to dispense a different build material. This is typically achieved by providing the printhead with multiple fluid channels spaced apart from each other, where each channel receives a different build material through a separate inlet and delivers it to a different nozzle array.

[0048] Therefore, different target locations can be occupied by different build material formulations. Build material formulations can be broadly categorized into two types: modeling material formulations and support material formulations. Support material formulations serve as a support matrix or structure during manufacturing and / or other applications to support objects or object components, for example, providing hollow or porous objects. The support structure may also include modeling material formulation elements, for example, to further enhance support strength.

[0049] Modeling material formulations are typically compositions designed specifically for additive manufacturing that can form three-dimensional objects on their own, without needing to be mixed or combined with any other substances.

[0050] The final 3D object is made from: a modeling material formulation or a combination of multiple modeling material formulations, or a combination of a modeling material formulation and a support material formulation, or a modification thereof (such as after curing). All of these operations are well known to those skilled in the art of solid freeform manufacturing.

[0051] In some exemplary embodiments of the present invention, an object is manufactured by dispensing two or more different modeling material formulations, each formulation originating from a different nozzle array (belonging to the same or different printheads) in an additive manufacturing (AM) apparatus. In some embodiments, the two or more nozzle arrays dispensing the different modeling material formulations are both located in the same printhead of the additive manufacturing apparatus. In some embodiments, the nozzle arrays dispensing the different modeling material formulations are located in separate printheads; for example, a first nozzle array dispensing a first modeling material formulation is located in a first printhead, and a second nozzle array dispensing a second modeling material formulation is located in a second printhead.

[0052] In some embodiments, the nozzle array for dispensing the modeling material formulation and the nozzle array for dispensing the support material formulation are both located in the same printhead. In some embodiments, the nozzle array for dispensing the modeling material formulation and the nozzle array for dispensing the support material formulation are located in different printheads.

[0053] Figure 1A The diagram illustrates a representative and non-limiting example of an AM system 110 suitable for object 112 according to some embodiments of the invention. System 110 includes an additive manufacturing apparatus 114 having a dispensing unit 16 comprising a plurality of printheads. Each head preferably includes one or more nozzle arrays 122, typically mounted on an orifice plate 121, as described below. Figure 2A As shown in -C, the liquid building material formulation 124 is dispensed through the nozzle array.

[0054] Preferably, but not necessarily, the apparatus 114 is a 3D printing apparatus, in which case the printhead is a print head and the build material formulation is dispensed via inkjet technology. However, this is not always the case, as for some applications, the additive manufacturing apparatus may not require 3D printing technology. Representative examples of additive manufacturing apparatuses contemplated according to various exemplary embodiments of the invention include, but are not limited to, fused deposition modeling apparatuses and fused material formulation deposition apparatuses.

[0055] Each printhead may selectively and preferably be fed through one or more build material formulation reservoirs, which may optionally include a temperature control unit (e.g., a temperature sensor and / or heating device) and a build material level sensor. To dispense the build material formulation, a voltage signal is applied to the printhead to selectively deposit droplets of the formulation through the printhead nozzles, for example, using piezoelectric inkjet printing technology. Another example includes thermal inkjet printheads. In these types of printheads, a heating element is in thermal contact with the build material formulation to heat the formulation and form bubbles therein when the voltage signal activates the heating element. The bubbles generate pressure in the build material formulation, causing droplets of the formulation to be ejected through the nozzles. Piezoelectric and thermal printheads are well known to those skilled in the art of solid freeform manufacturing. For any type of inkjet printhead, the dispensing rate depends on the number of nozzles, the type of nozzles, and the rate (frequency) of the applied voltage signal.

[0056] Optionally, the total number of distributing nozzles or nozzle arrays is selected such that half of the distributing nozzles are used to distribute the support material formulation, and the other half are used to distribute the modeling material formulation; that is, the number of nozzles spraying the modeling material formulation is the same as the number of nozzles spraying the support material formulation. Figure 1A In a representative example, four printheads 16a, 16b, 16c, and 16d are shown. Each printhead 16a, 16b, 16c, and 16d has a nozzle array. In this example, printheads 16a and 16b may be designated for modeling material formulations, while printheads 16c and 16d may be designated for support material formulations. Thus, printhead 16a may dispense one modeling material formulation, printhead 16b may dispense another modeling material formulation, and printheads 16c and 16d may both dispense support material formulations. In an alternative embodiment, for example, printheads 16c and 16d may be combined into a single printhead with two nozzle arrays for depositing support material formulations. In another alternative embodiment, any one or more printheads may have more than one nozzle array for depositing more than one material formulation; for example, two nozzle arrays may be used to deposit two different modeling material formulations, or one modeling material formulation and one support material formulation, each formulation passing through a different array or number of nozzles.

[0057] However, it should be understood that this is not intended to limit the scope of the invention, and the number of modeling material formulation printheads (modeling heads) and the number of support material formulation printheads (support heads) may differ. In some embodiments, the number of nozzle arrays dispensing the modeling material formulation, the number of nozzle arrays dispensing the support material formulation, and the number of nozzles in each respective array are selected to provide a predetermined ratio α between the maximum dispensing rate of the support material formulation and the maximum dispensing rate of the modeling material formulation. Preferably, the value of the predetermined ratio α is selected to ensure that in each formed layer, the height of the modeling material formulation is equal to the height of the support material formulation. Typical values ​​for α are approximately 0.6 to approximately 1.5.

[0058] The term “approximately” as used in this article refers to ±10%.

[0059] For example, when all nozzle arrays are working, for the case of α=1, the overall dispensing rate of the support material formulation is usually the same as the overall dispensing rate of the modeling material formulation.

[0060] The device 114 may include, for example, M modeling heads, each having an array of m nozzles consisting of p nozzles, and S support heads, each having an array of s nozzles consisting of q nozzles, such that M × m × p = S × s × q. Each of the M × m modeling arrays and the S × s support arrays can be manufactured as a separate physical unit, which can be assembled and disassembled from the array group. In this embodiment, each such array optionally and preferably includes its own temperature control unit and material preparation level sensor, and receives individually controlled voltage for operation.

[0061] Apparatus 114 may also include curing device 18, which may include any device configured to emit light, heat, etc., thereby causing the deposited material formulation to harden. For example, curing device 18 may include one or more radiation sources, which may be ultraviolet lamps, visible light lamps, or infrared lamps or other electromagnetic radiation sources, or electron beam sources, depending on the modeling material formulation used. In some embodiments of the invention, curing device 18 is used to harden or cure the modeling material formulation.

[0062] In addition to the curing apparatus 18, the device 114 optionally and preferably includes an additional radiation source 328 for solvent evaporation. The radiation source 328 optionally and preferably generates infrared radiation. In various exemplary embodiments of the invention, the curing apparatus 18 includes a radiation source that generates ultraviolet radiation, while the radiation source 328 generates infrared radiation.

[0063] In some embodiments of the invention, device 114 includes a cooling system 134, such as one or more fans.

[0064] The printhead and radiation source are preferably mounted in a frame or block 128, which is preferably movable back and forth above a tray 12, which serves as a working surface. In some embodiments of the invention, the radiation source is mounted in the block to follow the movement of the printhead, thereby at least partially hardening or solidifying the material formulation just dispensed by the printhead. The tray 12 is placed horizontally. According to general practice, an XYZ Cartesian coordinate system is chosen such that the XY plane is parallel to the tray 12. The tray 12 is preferably configured to be vertically movable (along the Z direction), typically downwards. In various exemplary embodiments of the invention, the apparatus 114 also includes one or more leveling devices 32, such as rollers 326. The leveling device 326 is used to straighten, flatten, and / or determine the thickness of a newly formed layer before forming a continuous layer thereon. The leveling device 32 preferably includes a waste collection device 136 for collecting excess material formulation generated during the leveling process. The waste collection device 136 may include any mechanism for conveying the material formulation to a waste bin or waste container.

[0065] During use, the printhead unit 16 moves along the scanning direction, referred to herein as the X direction, and selectively dispenses build material formulations in a predetermined configuration as it passes the tray 12. The build material formulations typically include one or more types of support material formulations and one or more types of modeling material formulations. After passing the printhead unit 16, the modeling material formulation is hardened by the radiation source 18. When the printhead passes in the reverse direction, returning to the starting point of the recently deposited layer, additional build material can be dispensed according to the predetermined configuration. During the forward and / or reverse passage of the printhead, the resulting layer can be straightened by a leveling device 32, which preferably follows the path of the printhead during its forward and / or reverse movement. Once the printhead returns to the starting point along the X direction, it can move to another location along the index direction (referred to herein as the Y direction) and continue building the same layer by reciprocating movement along the X direction. Alternatively, the printhead can move along the Y direction between forward and reverse movements or after multiple forward-reverse movements. A series of scans performed by the printhead to complete a single layer is referred to herein as a single scan cycle.

[0066] Once the layer is completed, tray 12 descends along the Z direction to a predetermined Z height, based on the required thickness of the subsequent layers to be printed. This process is repeated to form the three-dimensional object 112 layer by layer.

[0067] In another embodiment, the tray 12 can move within the layer along the Z-direction between the forward and reverse passes of the printhead unit 16. This Z-direction movement is performed to allow the leveling device to contact the surface in one direction while preventing contact in the other.

[0068] This embodiment considers the use of a liquid material formulation supply system 42, which includes one or more liquid material containers or cartridges 44 for supplying liquid material to the printhead. Supply system 42 can be used in additive manufacturing (AM) systems, such as system 110, in which case the liquid material in each container is a build material.

[0069] Controller 20 controls manufacturing apparatus 114 and optionally, and preferably, also controls supply system 42. Controller 20 typically includes electronic circuitry configured to perform control operations. Controller 20 preferably communicates with computer 24, which typically includes display 25 and transmits digital data related to manufacturing instructions based on computer object data (e.g., CAD configurations represented on a computer-readable medium in Standard Triangular Mesh Language (STL) format). Typically, controller 20 controls the voltage applied to each printhead or each nozzle array, and the temperature of the material formulation being constructed in each printhead or nozzle array.

[0070] Once the manufacturing data is loaded into controller 20, it can operate without user intervention. In some embodiments, controller 20 may receive additional input from the operator, for example, using a user interface 116 or computer 24 communicating with controller 20. User interface 116 may be of any type known in the art, such as, but not limited to, a keyboard, touchscreen, etc. For example, controller 20 may receive one or more types and / or properties of building material formulations as additional input, including but not limited to color, characteristic deformation and / or transition temperature, viscosity, electrical properties, and magnetic properties. Other properties and groups of properties may also be considered.

[0071] Figure 1B -D shows another representative and non-limiting example of a system 10 for additive manufacturing of an object according to certain embodiments of the present invention. Figure 1B -D shows a top view of system 10 ( Figure 1B ), side view ( Figure 1C ) and isometric view ( Figure 1D ).

[0072] In this embodiment, system 10 includes a tray 12 and a plurality of inkjet printheads 16, each inkjet printhead having one or more nozzle arrays, each nozzle array having one or more separate nozzles. Material for 3D printing is supplied to the heads 16 by a build material supply system 42 having one or more liquid material containers or cartridges (not shown), as described in further detail above. The tray 12 may be disc-shaped or annular. Non-circular shapes are also conceivable, as long as they can rotate about a vertical axis.

[0073] The tray 12 and head 16 are optionally and preferably mounted to allow relative rotational movement between the tray 12 and head 16. This can be achieved by (i) configuring the tray 12 to rotate relative to the head 16 about a vertical axis 14, (ii) configuring the head 16 to rotate relative to the tray 12 about a vertical axis 14, or (iii) configuring both the tray 12 and the head 16 to rotate about a vertical axis 14, but at different speeds (e.g., rotating in opposite directions). While configuration (i) is specifically emphasized below to describe some embodiments of system 10, in which the tray is a rotating tray configured to rotate relative to the head 16 about a vertical axis 14, it should be understood that configurations (ii) and (iii) of system 10 are also contemplated in this application. Any embodiment of system 10 described herein can be adapted to suit any of configurations (ii) and (iii), and those skilled in the art will know how to make such adaptations upon receiving the details described herein.

[0074] In the following description, the direction parallel to tray 12 and pointing outward from axis 14 is called the radial direction r, and the direction parallel to tray 12 and perpendicular to the radial direction r is called the azimuth direction. Here, the direction perpendicular to tray 12 refers to the vertical direction z.

[0075] The radial direction r in system 10 corresponds to the index direction y in system 110, and the azimuth direction This corresponds to the scan direction x in system 110. Therefore, the radial direction is interchangeably referred to as the index direction in this document, and the azimuth direction is interchangeably referred to as the scan direction in this document.

[0076] As used herein, the term "radial position" refers to a position on or above the tray 12 at a specific distance from the axis 14. When used in conjunction with the printhead, the term refers to the position of the printhead at a specific distance from the axis 14. When used for a point on the tray 12, the term corresponds to any point belonging to a point trajectory, which is a circle with a radius of a specific distance from the axis 14 and a center at the axis 14.

[0077] As used herein, the term "azimuth position" refers to the position of a point on or above the tray 12 at a specific azimuth angle relative to a predetermined reference point. Therefore, radial position refers to any point belonging to a point trajectory, which is a straight line forming a specific azimuth angle relative to the reference point.

[0078] As used in this article, the term "vertical position" refers to the position above a plane where it intersects the vertical axis 14 at a specific point.

[0079] Tray 12 serves as the build platform for 3D printing. The working area for printing one or more objects is typically (but not necessarily) smaller than the total area of ​​tray 12. In some embodiments of the invention, the working area is annular. The working area is shown as 26. In some embodiments of the invention, tray 12 rotates continuously in the same direction during object formation; while in other embodiments, the tray reverses its rotation direction at least once during object formation (e.g., in an oscillating manner). Tray 12 is selectively and preferably removable. Removal of tray 12 may be for maintenance of system 10, or, if necessary, to replace the tray before printing a new object. In some embodiments of the invention, system 10 is equipped with one or more different replacement trays (e.g., a set of replacement trays), wherein two or more trays are designated for different types of objects (e.g., different weights), different operating modes (e.g., different rotation speeds), etc. Replacement of tray 12 can be performed manually or automatically as needed. When automatic replacement is used, system 10 includes a tray replacement device 36 configured to remove tray 12 from its position below printhead 16 and replace it with a replacement tray (not shown). Figure 1B In the representative schematic diagram, the pallet changing device 36 is shown as a driver 38 with a movable arm 40 configured to pull the pallet 12, but other types of pallet changing devices may also be considered.

[0080] Figure 2A-2C An exemplary embodiment of printhead 16 is shown. These embodiments can be used in any of the additive manufacturing (AM) systems described above, including but not limited to system 110 and system 10.

[0081] Figure 2A -B indicates that each has one ( Figure 2A ) and two ( Figure 2B The printhead 16 is a nozzle array 22. The nozzles in the array are preferably arranged linearly in a straight line. The printhead 16 is supplied with liquid material and dispenses the liquid material through the nozzle array 22 in response to a voltage signal applied by the controller of the printing system. The printhead 16 is supplied with liquid material as a building material formulation.

[0082] In embodiments where a particular printhead has two or more linear nozzle arrays, the nozzle arrays may optionally and preferably be parallel to each other. When the printhead has two or more nozzle arrays (e.g., Figure 2B All arrays of the printhead can be supplied with the same build material formulation, or at least two arrays of the same printhead can be supplied with different build material formulations.

[0083] When using a system similar to system 110, all printheads 16 can be selectively and preferably oriented along the index direction, while their positions along the scanning direction are offset from each other.

[0084] When using a system similar to System 10, all printheads 16 can be selectively and preferably radially oriented (parallel to the radial direction), and their azimuth positions are offset from each other. Therefore, in these embodiments, the nozzle arrays of different printheads are not parallel to each other, but rather at an angle to each other, which is approximately equal to the azimuth offset between the individual printheads. For example, a printhead can be radially oriented and located at an azimuth position. 1. The other printhead can be radially oriented and located at an azimuth angle. 2. In this example, the azimuth offset between the two printheads is... 1 - 2, and the angle between the linear nozzle arrays of the two printheads is also . 1 - 2.

[0085] In some embodiments, two or more printheads may be assembled into a printhead block, in which case the printheads in the block are typically parallel to each other. Figure 2C A printhead block containing multiple inkjet printheads 16a, 16b, and 16c is shown.

[0086] In some embodiments, system 10 includes a stabilizing structure 30 located below printhead 16, such that tray 12 is positioned between the stabilizing structure 30 and printhead 16. The stabilizing structure 30 can be used to prevent or reduce vibrations that may occur to tray 12 during operation of the inkjet printhead 16. In a configuration where printhead 16 rotates about axis 14, the stabilizing structure 30 also preferably rotates to ensure that the stabilizing structure 30 is always positioned directly below printhead 16 (with tray 12 positioned between printhead 16 and tray 12).

[0087] The tray 12 and / or printhead 16 may be selectively and preferably configured to move in a vertical direction z parallel to the vertical axis 14 to change the vertical distance between the tray 12 and the printhead 16. In the configuration where the vertical distance is changed by moving the tray 12 in a vertical direction, the stabilizing structure 30 also preferably moves vertically together with the tray 12. In the configuration where the vertical distance is changed by moving the printhead 16 in a vertical direction, the stabilizing structure 30 remains in a fixed vertical position while keeping the vertical position of the tray 12 fixed.

[0088] Vertical movement can be achieved via vertical driver 28. Once one layer is completed, the vertical distance between tray 12 and printhead 16 can be increased (e.g., by lowering tray 12 relative to printhead 16) by a predetermined vertical step, depending on the required thickness of the subsequent layers to be printed. This process is repeated to form a three-dimensional object layer by layer.

[0089] The operation of the inkjet printhead 16, as well as (optionally and preferably) the operation of one or more other components of the system 10 (e.g., the movement of the tray 12), is controlled by the controller 20. This controller may be equipped with electronic circuitry and a non-volatile storage medium readable by the circuitry, wherein the storage medium stores program instructions that, when read by the circuitry, cause the circuitry to perform control operations as detailed further below.

[0090] The controller 20 can also communicate with the host computer 24, which transmits digital data related to manufacturing instructions based on computer object data, such as in Standard Mesh Language (STL) or Stereolithography Profile (SLC) format, OBJ file format (OBJ), 3D Manufacturing Format (3MF), Virtual Reality Modeling Language (VRML), Additive Manufacturing File (AMF) format, Graphics Exchange Format (DXF), Polygon File Format (PLY), or any other format suitable for computer-aided design (CAD). The object data format is typically structured according to a Cartesian coordinate system. In these cases, the computer 24 preferably executes a program that transforms the coordinates of each slice in the computer object data from the Cartesian coordinate system to a polar coordinate system. The computer 24 may selectively and preferably transmit manufacturing instructions according to the transformed coordinate system. Alternatively, the computer 24 may transmit manufacturing instructions according to the original coordinate system provided by the computer object data, in which case the coordinate transformation is performed by the circuitry of the controller 20.

[0091] Coordinate transformation enables 3D printing on a rotating pallet. In a non-rotating system, the pallet remains fixed, and the printhead typically moves back and forth in a straight line above the fixed pallet. In this system, the printing resolution is the same at any point on the pallet, provided the printhead's dispensing rate is uniform. Unlike the non-rotating system, in system 10, the distances covered by all the nozzles of the printhead on the pallet 12 at the same time are not uniform. Coordinate transformation is an optional and preferred method of execution to ensure that the amount of excess material at different radial locations is equal. Figure 3A -B provides a representative example of coordinate transformation according to certain embodiments of the present invention, showing three slices of an object (each slice corresponding to manufacturing instructions for a different layer of the object), wherein Figure 3A The slice is shown in the Cartesian coordinate system. Figure 3B This shows the same slice after applying a coordinate transformation procedure to the corresponding slice.

[0092] Typically, controller 20 controls the voltage applied to the various components of system 10 according to manufacturing instructions and stored program instructions described below.

[0093] Typically, during the rotation of the tray 12, the controller 20 controls the print head 16 to dispense droplets of the building material formulation layer by layer, thereby printing a three-dimensional object on the tray 12.

[0094] System 10 optionally and preferably includes one or more curing devices 18, such as, but not limited to, radiation sources. Depending on the modeling material formulation used, the radiation source may be, for example, an ultraviolet lamp, a visible light lamp, an infrared lamp, or other electromagnetic radiation source, or an electron beam source. The radiation source may include any type of radiation emitting device, including but not limited to light-emitting diodes (LEDs), digital light processing (DLP) systems, resistive lamps, etc. The curing device 18 is used to harden or cure the modeling material formulation. In various exemplary embodiments of the invention, the operation of the curing device 18 is controlled by a controller 20, which can start and stop the curing device 18 and selectively control the amount of radiation generated by the curing device 18.

[0095] In some embodiments of the invention, system 10 further includes one or more leveling devices 32, which may be manufactured in the form of rollers or scrapers. The leveling devices 32 are used to flatten newly formed layers before a continuous layer is formed thereon. In some embodiments, the leveling devices 32 are shaped like tapered rollers such that their axis of symmetry 34 is inclined relative to the surface of the tray 12, while their surface is parallel to the surface of the tray. This embodiment is shown in a side view of system 10 (…). Figure 1C This is explained in ( ).

[0096] Conical rollers can be conical or frustum-shaped.

[0097] The angle of the conical roller is preferably chosen such that the radius of the cone at any position along its axis 34 remains in a constant ratio to the distance between that position and the axis 14. This embodiment allows the roller 32 to effectively level the layers because, as the roller rotates, the linear velocity of any point p on the roller surface is proportional (e.g., the same) to the linear velocity of a point on the tray perpendicularly below point p. In some embodiments, the roller is frustum-shaped with a height h, a radius R1 closest to the axis 14, and a radius R2 furthest from the axis 14, where the parameters h, R1, and R2 satisfy the relationship R1 / R2 = (Rh) / h, where R is the furthest distance of the roller from the axis 14 (e.g., R can be the radius of the tray 12).

[0098] The operation of the leveling device 32 may optionally and preferably be controlled by a controller 20, which can start and stop the leveling device 32 and can also selectively control its position in the vertical direction (parallel to axis 14) and / or the radial direction (parallel to tray 12 and pointing towards or away from axis 14).

[0099] In some embodiments of the invention, the printhead 16 is configured to reciprocate relative to the tray in a radial direction r. These embodiments are particularly useful when the length of the nozzle array 22 of the printhead 16 is less than the radial width of the working area 26 on the tray 12. The radial movement of the printhead 16 is optionally and preferably controlled by the controller 20.

[0100] Some embodiments envision manufacturing objects by dispensing different material formulations from different nozzle arrays (belonging to the same or different printheads). These embodiments particularly provide the ability to select material formulations from a given number of material formulations and define desired combinations of the selected material formulations and their properties. According to this embodiment, the spatial location of each material formulation's deposition within the layer is defined to allow different material formulations to occupy different three-dimensional spatial locations, or to allow two or more different material formulations to occupy substantially the same or adjacent three-dimensional locations, thereby allowing post-depositional spatial combination of material formulations within the layer to form composite formulations at one or more corresponding locations.

[0101] Combinations or mixtures of any post-deposition modeling material formulations can be considered. For example, once a material formulation is dispensed, it may retain its original properties. However, when it is dispensed simultaneously with another modeling material formulation or other dispensed material formulations dispensed at the same or proximal locations, a composite formulation with properties different from the dispensed material formulations may be formed.

[0102] In some embodiments of the present invention, for at least one layer, the system distributes two or more formulations to form a digital modeling material.

[0103] The term “digital modeling material,” as used herein and in the art, describes a combination of two or more materials at the pixel or voxel level, such that pixels or voxels of different material formulations are distributed in an interlaced manner within a region, and then hardened (e.g., cured) to form an interlaced pattern of hardened material voxels, the interlacing being along multiple directions.

[0104] Digitally modeled materials may exhibit novel properties that are influenced by the choice of material formulation type and / or the proportion and relative spatial distribution of two or more material formulations.

[0105] In this specification, a "voxel" in "layer" refers to a physical three-dimensional basic volume within a layer, which corresponds to a single pixel in the bitmap describing that layer. Once the building material is assigned to the positions corresponding to the individual pixels, and after leveling and curing, the size of the voxel is approximately the size of the area formed by the building material.

[0106] Therefore, embodiments of the present invention are capable of depositing various material formulation combinations and, depending on the desired characteristics of each part of the object, manufacturing objects that may be composed of multiple different material formulation combinations in different parts of the object.

[0107] For more detailed information on the principles and operation of the additive manufacturing (AM) system applicable to this embodiment, please refer to U.S. Patent No. 9,031,680 and International Publication No. WO2022 / 024114, the contents of which are hereby incorporated by reference.

[0108] In some embodiments of the invention, system 10 and / or system 110 are configured to print one or more objects on a fabric.

[0109] As used herein, “fabric” includes any article made at least in part from natural or man-made fiber materials. Examples of fabric types include, but are not limited to: clothing, shoes, toys, textiles, carpets, hats, bags, socks, towels, curtains, etc.

[0110] This embodiment considers printing on woven or non-woven fabrics.

[0111] As used herein, “weave” means a structure formed by interlacing (e.g., perpendicular to each other) at least two sets of threads according to a predetermined weave pattern, and at least one set of threads is parallel to the longitudinal axis of the fabric, according to ASTM D123-03.

[0112] As used in this article, the term "nonwoven" refers to a textile structure formed by bonding or locking fibers together, or both, through mechanical, chemical, thermal, or solvent means or combinations thereof, in accordance with ASTM D123-03.

[0113] Preferably, but not necessarily, when printing objects on fabric using a printing system (e.g., system 10 or 110), the leveling device 32 is not used for at least some layers. In these embodiments, each layer of build material applied to the fabric cures (e.g., hardens) immediately after application without the need for leveling.

[0114] Preferably, but not necessarily, when printing objects on fabric using a printing system (such as system 10 or 110), the height of the printed object should be less than 10 cm, more preferably less than 9 cm, more preferably less than 8 cm, more preferably less than 8 cm, more preferably less than 7 cm, more preferably less than 6 cm, more preferably less than 5 cm, more preferably less than 4 cm, more preferably less than 3 cm, more preferably less than 2 cm, and most preferably less than 1 cm.

[0115] In some embodiments of the invention, the process of fabricating a three-dimensional object on a fabric includes dispensing one or more layers of material onto the fabric, on which the object is formed. The material, alone or in conjunction with a fabric pretreatment process (e.g., chemical, thermal, and / or mechanical treatment), acts as an adhesive to ensure adhesion between the fabric and the object. In some embodiments of the invention, the material may be a modeling material, such as, but not limited to, Stratasys Ltd.'s Vero™ and / or VeroUltra™ (e.g., VeroUltra). TM Modeling materials sold under the trade name Clear are relatively hard once cured. Other materials considered include, but are not limited to, VeroFlex sold by Stratasys Ltd. TM and VeroEco TM Flex.

[0116] Traditional Advanced Machine Design (AM) systems can print 3D objects based on computer object data, which is prepared according to the 3D shape of the object. In such systems, the operator selects the shape of the object to be manufactured, for example, through appropriate software (such as CAD software). This software then generates computer object data in the form of graphical elements (such as polygonal meshes, non-uniform rational basis splines, etc.), which define the object's surface. The computer processes these graphical elements using software called a "slicer," transforming them into voxel meshes. These voxel meshes define the object's internal shape and are arranged into multiple slices, each containing multiple voxels, describing one layer of the 3D object.

[0117] The inventors have discovered that such systems can be significantly improved by allowing operators to select two-dimensional images, as acquiring or preparing two-dimensional images is easier than preparing the three-dimensional shape of an object. Therefore, this embodiment provides a design tool that allows an end-user to select a two-dimensional image and generate computer object data based on that selection. This data can be used by an additive manufacturing (AM) system to manufacture a three-dimensional object corresponding to the selected two-dimensional image. The computer object data generated by the design tool can typically be stored in a computer-readable storage medium as one or more computer files. In various exemplary embodiments of the invention, the three-dimensional object described by the computer object data includes a plurality of discrete raised elements that collectively constitute a relief pattern, which is a three-dimensional representation of the image information contained in the selected two-dimensional image.

[0118] This design tool is particularly useful for creating three-dimensional objects on fabrics because the raised element structure of the created objects maintains the flexibility of the fabric.

[0119] The design tool in this embodiment uses a graphical user interface (GUI), which is displayed by a computer (such as computer 24) on a display device (such as display device 25 of computer 24) or user interface 116. The GUI provides an easy-to-use interface between the end user of the additive manufacturing (AM) system and the computer. The GUI contains multiple computer-generated objects referred to as “GUI controls,” or more simply, “controls.” Multiple GUI controls can be grouped together, called a “control group.” While a control group typically contains two or more GUI controls, the term “control group” as used below also includes the specific case where the control group contains only a single GUI control. Representative examples of GUI controls suitable for this embodiment include, but are not limited to, sliders, drop-down menus, combo boxes, text boxes, toggle buttons, rotary selectors, etc.

[0120] GUI controls are operated by dedicated software and respond to physical actions performed by the user via a device that sends signals to the computer. Such a device can be a computer mouse, touchscreen, keyboard, etc., and may optionally include a microphone, in which case the computer is configured to execute voice-activated software. The GUI may optionally and preferably display additional information, such as non-interactive text and graphics.

[0121] During operation, the end user can select and activate controls to initiate operations performed by the computer's processor. The software operating the graphical user interface (GUI) sends activation signals to the processor, for example, by configuring input / output (I / O) circuitry for passing signals between the GUI and the processor. Activation signals can be sent to the processor when the corresponding control is activated, or they can be sent at a later time (e.g., when another control is activated). Controls are presented on the GUI as graphical elements, which may optionally and preferably be labeled in a way that indicates the operations the processor should perform in response to the activation of these controls. Controls can be arranged according to a predefined layout, or they can be dynamically created and / or removed based on specific actions taken by the end user through other GUI controls. For example, a user can select a button to turn another control on or off, expand a control, display an image, and / or switch between GUI layouts (often referred to as GUI screens or tabs).

[0122] The graphical user interface (GUI) of this embodiment receives input from the end user related to one or more two-dimensional images via GUI controls, and optionally and preferably also receives input related to one or more features of raised elements to form an embossed pattern, which represents image information in the two-dimensional images. In response to the activation of one or more GUI controls, the computer's input / output (I / O) circuitry transmits signals related to the input from the GUI to the processor, which converts these signals into computer object data describing the embossed pattern. The processor then saves the computer object data to a computer-readable storage medium.

[0123] Figure 4A -E illustrates a representative example of a GUI 400 applicable to this embodiment. The GUI 400 includes multiple control groups, the details of which will be described below. In the illustrated embodiment (which should not be considered a limiting example), the control groups are arranged across multiple screens. Figure 4A -E represents "Screen 1", "Screen 2", "Screen 3", etc. These multiple screens can be displayed simultaneously (e.g., side by side) or sequentially. The GUI 400 can include one or more screen selectors 402 to allow the end user to instruct the GUI 400 which screen to display.

[0124] The graphical user interface (GUI) 400 includes an image selection control group 404, such as Figure 4A As shown. In a representative example, an image selection control group 404 is displayed on “Screen 1” of the GUI 400. The control group 404 allows the user to select a two-dimensional image stored in a computer-readable medium. In some embodiments of the invention, the user is allowed to select more than one two-dimensional image. Typically, the control group 404 includes a text box or browse control 406, allowing the user to enter or select the address of an image. The control group 404 may include an image preview area 416 for displaying the selected image therein. The control group 404 may also optionally and preferably include a control 408, allowing the user to enter the physical dimensions of the three-dimensional object to be manufactured. Preferably, the control group 404 includes a control 410, such as, but not limited to, a drop-down menu, allowing the user to select an additive manufacturing (AM) system to manufacture the object. In these embodiments, the GUI 400 is configured to warn the user when the dimension entered in the control 408 exceeds the size of the tray (e.g., tray 12) of a particular AM system. Optionally, the GUI 400 may prevent the user from entering a dimension exceeding the tray size. However, this is not always necessary, as in some applications it may be beneficial to allow designs of larger objects that can be manufactured piece by piece via an AM system.

[0125] The image selection control group 404 may also include multiple image manipulation controls, such as a geometric manipulation control 412 that allows geometric operations such as rotation, flipping, and / or mirroring; and a masking manipulation control 414 that allows masking of an image based on color or grayscale level or an input pattern or drawing.

[0126] Once an image is selected via control 406, the processor can selectively and preferably identify background regions 418 and non-background regions 419 within the image. This can be achieved using any image processing technique known in the art, including but not limited to color-based segmentation, edge-based background removal, entropy filtering, alpha matting, etc. Alternatively, depending on the format of the image data contained in the two-dimensional image, the background can be identified via one or more specific channels of the image data. For example, image data in the Portable Network Graphics (PNG) format contains an alpha channel that can be used to identify the background of the image. The identification of background regions 418 and non-background regions 419 can be performed immediately upon loading the image data or in response to activation of the background identification control 417.

[0127] GUI 400 may also include a tile selection control group 420, such as Figure 4B As shown. In a representative example, a tile selection control group 420 is displayed on “Screen 2” of the GUI 400. The control group 420 allows the user to select a tile pattern 426. Based on the selected tile pattern 426, the processor defines a plurality of discrete tile elements 422, each tile element being associated with a different local portion of image data contained in a two-dimensional image. When the control group 404 selects multiple images, all tile elements 422 are preferably associated with a corresponding portion of image data contained in one of the selected two-dimensional images. Preferably, the tile pattern 426 is defined only on non-background areas of the image. Preferably, the tile pattern 426 substantially follows the outline of the two-dimensional image.

[0128] The control group 420 optionally and preferably includes one or more tile pattern preview areas 424 for displaying a preview of the selected tile pattern 426 or a portion thereof. The selection of the tile pattern 426 can be accomplished in various ways. In some embodiments of the invention, the control group 420 includes controls 428, 430, and 432 for selecting (optionally and preferably independently) the shape (control 428) and size, or equivalent density (control 430), and (optionally and preferably) the spacing between adjacent tile elements 422 (control 432) for each tile element 422. Optionally, the tile selection control group 420 allows the user to select different sizes for different tile elements and / or different spacings for different pairs of tile elements.

[0129] In some embodiments of the invention, the tile selection control group 420 allows a user to load one or more maps containing information relating to the shape, size (or equivalent density), and / or spacing of the tiled elements 422 in a two-dimensional image. In these embodiments, the processor selects one or more features of the element 422 based on information in the respective map.

[0130] In any of the above embodiments, representative examples of the shape of the tiled element 422 selectable via control group 420 include, but are not limited to, polygons (e.g., triangles, pentagons, hexagons, octagons, and quadrilaterals such as rectangles), circles, ellipses, etc. Preferably, but not necessarily, the shape is convex. When the shape is a polygon, it is optionally and preferably a regular polygon.

[0131] Tiling a two-dimensional image using the tiling pattern 426 can be achieved using any image processing technique known in the art. In a representative example of this process, the two-dimensional image is segmented into superpixels, for example, by applying commercial image processing functions, such as, but not limited to, Matlab. ® The software provides the "superpixels" function. Then, each superpixel is represented by a single point, for example, by applying a shrinkage function to the superpixels. Suitable shrinkage functions can be found in Matlab. ® This is obtained through an option in the software's `bwmorph` function. A Voronoi diagram is then constructed based on the obtained individual points, thus tiling the 2D image. The advantage of this method is that it provides a tiling pattern that follows a 2D contour. Another suitable technique for forming a tiling pattern that follows a 2D contour involves dividing one or more superpixels into convex polygons. This can be achieved using any commercial image processing function, such as, but not limited to, Matlab. ® The "coverageDecomposition" function in the UAV Toolbox of the software. A combination of the above procedures can also be considered. In some embodiments of the invention, the amount of perturbation to the position of a point depends on one or more features of the two-dimensional image. For example, points located in regions with small standard deviations of image values ​​may be subject to significant perturbation.

[0132] Two-dimensional images can be tiled using the tiling pattern 426, alternatively or additionally based on the image data of the two-dimensional image itself. A representative example of the image processing procedure applicable to this embodiment is as follows: A map of values ​​is created based on the image data. This map associates specific values ​​with each pixel of the image based on the pixel's color, hue, grayscale label, or contrast, or based on the distance between pixels in the image, as is known in the art. Once the map of values ​​is created, gradients are calculated on the map using the map values. The map values ​​and gradients are then used to form a vector field with multiple discrete vectors. For example, the direction of the vectors in the field can define the gradient, and the length of the vectors can define the map values. A geometric transformation is performed on the vector field, transforming the discrete vectors into a grid with a predetermined geometry. This geometry is optionally and preferably compatible with the shape of the tiling element selected by the control group 420. For example, when the selected shape is a square, the grid is a rectangular grid; when the selected shape is a triangle, the grid is a triangular grid; when the selected shape is a hexagon, the grid is a hexagonal grid; and so on. The cells of the grid are then defined as tiling elements 422.

[0133] The graphical user interface (GUI) 400 may also include an embossed selection control group 440, such as Figure 4C As shown in the representative illustration, the emboss selection control group 440 is displayed on "Screen 3" of the GUI 400. The control group 440 allows the user to select a three-dimensional shape for the raised elements 450 that form the embossed pattern 458, which, as previously described, is a three-dimensional representation of image information contained in the selected two-dimensional image. Each raised element 450 extends from one of the tiled elements, thus the corresponding tiled element serves as the base of the raised element 450. Each raised element 450 has one or more intensity levels depending on a different portion of the image data (e.g., the portion associated with the corresponding tiled element). The intensity level of the raised element can be a grayscale level of the tiled element, or a set of intensity levels that collectively define the color of the tiled element using a color coordinate system.

[0134] In embodiments where two images are selected, the intensity levels at different segments of the raised element can optionally and preferably be selected based on different images. For example, the intensity level at the lower part of the raised element can be based on one image, while the intensity level at the upper part of the raised element can be based on the other image. This can be easily achieved by setting a predetermined vertical position threshold h, i.e., for all points in the raised element with vertical coordinates less than h, the intensity level is based on one image, while for all other points in the raised element, the intensity level is based on the other image. The inventors unexpectedly discovered that selecting the intensity levels at different segments of the raised element based on different images can create a lens-like effect for the manufactured relief pattern, so that the same relief pattern presents different views when viewed from different angles.

[0135] The total height of the raised element 450 may be uniform or non-uniform throughout the image. The control group 440 may optionally and preferably include a preview area 442 in which a preview of the selected raised element 450 is displayed, and optionally and preferably also displays an embossed pattern 458. In some embodiments, the preview of the embossed pattern 458 is displayed alternately or additionally by different control groups (e.g., on different screens of the GUI 400).

[0136] In the simplest implementation of GUI 400, control group 440 automatically selects the three-dimensional shape and size of each protrusion element 450. For example, control group 440 can select a dome shape and a uniform height for the protrusion element 450. In some embodiments of the invention, control group 440 may include a shape selector 442, for example, in the form of a drop-down menu, providing the user with a series of shape options to choose from. Representative examples of three-dimensional shapes suitable for this embodiment are as follows: Figure 5A As shown in -F, including but not limited to cones ( Figure 5A ), dome ( Figure 5B ),hemisphere( Figure 5C ), chamfer ( Figure 5D ), rounded corners ( Figure 5E ) and straight cylinder ( Figure 5F ). Figure 5A The shape shown in -F has a circular base, and is therefore suitable for cases where the corresponding tile element is circular. Those skilled in the art, upon understanding the details described herein, will know how to modify it. Figure 5A -F can be applied to tile elements of other shapes. In some embodiments of the invention, shape selector 442 selects a shape for the entire raised element, while in other embodiments, shape selector 442 selects a shape only for the top of the raised element, wherein the other parts of the raised element are right extrusions of the shapes of the corresponding tile elements.

[0137] review Figure 4C The control group 440 may optionally and preferably include a height selector 444 (shown as a slider in the example diagram) for selecting the height of each raised element (in the case of a uniform height) or the maximum permissible height of the raised elements. In some embodiments of the invention, the control group 440 also includes a minimum height selector 446 (also shown as a slider in the example diagram) for selecting the minimum height of the raised elements. When the heights of the raised elements in the two-dimensional image are non-uniform, the height of all raised elements is at least the minimum height selected by control 446 and at most the height selected by control 444.

[0138] The cross-sectional dimensions of the raised element 450 may be the same along its entire length, or they may vary along at least one segment of the raised element 450. Typically, at the base of the raised element, the cross-sectional dimensions are set by the dimensions of the corresponding tiling element, while in other parts of the raised element, the cross-sectional dimensions are either the same as at the base or vary as shown in the diagram. Figure 4C As shown, the distance from the base changes monotonically as a function of distance. It is also conceivable that an embodiment in which control group 440 includes a cross-sectional size selector (not shown), which could replace control 430 of control group 420.

[0139] The spacing between raised elements 450 is typically set by the spacing between adjacent tiled elements. It is also conceivable that an embodiment in which control group 440 includes a spacing selector (not shown) which may replace control 432 of control group 420.

[0140] When the height of the raised elements is non-uniform, the control group 440 can select the height in a variety of ways. In some embodiments of the invention, the control group 440 selects the height of each individual raised element based on a portion of the image data associated with each tile element. For example, the selection can be based on a rule that takes the color, hue, or grayscale level of the image data as input and provides the height of the corresponding raised element based on that input. Thus, in these embodiments, the processor reads the image data of each tile element and uses the rule to select the height of the raised element to be raised from that tile element. As a non-limiting example, the rule could result in raised elements being taller in darker areas of the image and shorter in brighter areas. The control group 440 may include a height rule selector 448 that allows the user to select a rule using the image data to define the height of the raised elements.

[0141] For example, the height rule selector 448 can allow selection between the following options: the option to assign a higher embossed element to a darker area, the option to assign a higher embossed element to a lighter area, the option to assign a higher embossed element to a red area, the option to assign a higher embossed element to a green area, the option to assign a higher embossed element to a blue area, the option to assign a higher embossed element to a yellow area, and so on.

[0142] In some embodiments of the invention, the height rule selector 448 includes an option to select the height of each individual raised element based on a height map. The height map preferably associates each tile element of the tiled pattern with a raised element height, and the control group 440 can set the height of each raised element 450 based on height values ​​for each tiled element stored in the map. The height map may be generated in response to user input or automatically, or it may be loaded from a computer-readable medium. Representative examples of control groups suitable for allowing a processor to generate height maps are provided below.

[0143] The emboss selection control group 440 may also include a fineness selector 452 for allowing the user to select the fineness of the raised element. Typically, based on the selected fineness, the processor defines the tessellation resolution for the curved portions of the raised element. Figure 7A and 7B A preview area 442 shows two example values ​​input into the fineness selector 452, where Figure 7A The fineness value is higher than Figure 7B The precision value.

[0144] The emboss selection control group 440 may also include a transparency control 454, which allows the user to select whether and to what extent to use transparent building materials to create raised elements. Typically, but not necessarily, during AM fabrication, the selected transparency is applied only to the top of the raised elements.

[0145] The term "transparent" describes the property of a material, specifically its transmittance, which reflects the amount of light that passes through it. Transparent materials are typically characterized by their ability to transmit at least 70% of the light that passes through them, or by a transmittance of at least 70%. The transmittance of a material can be determined using methods well-known in the art.

[0146] Representative examples of modeling materials suitable for creating transparent raised elements include, but are not limited to, the following materials: trade names RGD720, MED610™, MED625FLX™, and VeroClear™, all of which are available from Stratasys, Israel. Other transparent modeling materials are described in international publications WO 2020 / 065654 and WO 2021 / 014434. During AM (Advanced Modeling) of raised elements, the transparency level of the raised element can be controlled by appropriately selecting the ratio between opaque and transparent materials in the digital material forming the raised element.

[0147] The mitigation selection control group 440 may also include a severity selection control 456. Typically, the processor defines the curvature of the curved portion of the raised element based on the selected severity. Figure 8A and 8B Preview area 442 shows two example values ​​for the input severity selector 456, where Figure 8A The severity value is higher than Figure 8B The severity value.

[0148] GUI 400 may also include Figure 4D The illustrated lensing control group 460 is shown. In a representative illustration, the lensing control group 460 is displayed on “Screen 4” of the GUI 400. The control group 460 allows the user to select whether to apply lensing, and optionally and preferably also select a lensing scheme. Lensing is achieved by manufacturing the top of the raised element into a lens (e.g., in the shape of a dome or hemisphere) and coloring its base with multiple colors, so that beams of light of different colors are refracted in different directions by the lens, creating the illusion that the image represented by the manufactured relief pattern changes when viewed from different directions. This can be achieved by intelligently selecting at least one of the shape, color, and transparency level of the raised element 450. The control group 460 may include a lensing preview area 470, which provides a view of the selected image after lensing is applied. In some embodiments of the invention, the control group 460 includes a preview switch 468, wherein when the switch 468 is activated, the preview area 470 displays the image after lensing, and when the switch 468 is not activated, the preview area 470 displays the image before lensing.

[0149] The control group 460 preferably includes a lens activation button 462 and an indicator 464 highlighted when the button 462 is activated. After the button is activated, the processor can automatically select a lensing scheme. The lensing scheme may include at least one of the following: the color of the tiled element used as the base of the raised element, the focal length of the lens forming the top of the raised element, and the transparency level of the raised element.

[0150] In some embodiments of the invention, control group 460 allows the user to select a lensing scheme. Typically, control group 460 includes a color picker 464 through which the user selects the base color. The user can select two or more colors individually, or select a single color, in which case GUI 400 automatically selects one or more other colors based on a predetermined color scheme (e.g., inverse colors in a two-color scheme, and three colors in a three-color scheme). Embodiments where GUI 400 automatically selects colors based on the color of the tiled element itself are also conceivable.

[0151] For example, when using a two-color scheme, GUI 400 divides each tiled element into two regions. The first region is colored using the original color of the input 2D image at the location of the tiled element, and the second region is colored using a color opposite to the color of the first region. Similarly, when using a three-color scheme, GUI 400 divides each tiled element into three regions. The first region is colored using the original color of the input 2D image at the location of the tiled element, and the second and third regions are each colored using colors that form a triplet with the color of the first region.

[0152] Control group 460 includes a lens intensity selector 466, through which a user can select the intensity of the lensing. The processor can use the user-selected intensity to select at least one of the following: the focal length of the lens, the relative intensity of the color selected by selector 464, and the transparency level of the raised element.

[0153] Any of the aforementioned features that form the relief pattern on the object may be non-uniform on the object. This non-uniformity can be achieved by using one or more maps that locally assign the corresponding features on the image. For example, when it is desired that the height of the raised elements be non-uniform on the object, the processor can use a height map to select the height; when it is desired that the density of the raised elements be non-uniform on the object, the processor can use a density map to select the height; when it is desired that the cross-sectional dimensions of the raised elements be non-uniform on the object, the microprocessor can use a size map to select the cross-sectional dimensions; when it is desired that the shape of the base of the raised elements (or equivalently, the shape of the tiling elements) be non-uniform on the object, the processor can use a shape map to select the shape; when it is desired that the spacing between the raised elements be non-uniform on the object, the processor can use a spacing map to select the spacing between the raised elements; and when it is desired that the lensing scheme be non-uniform on the object, the processor can use a lensing map to select the lensing scheme.

[0154] One or more maps can be loaded from a computer-readable storage medium, or they can be generated based on user selection, such as generating control groups from maps. Figure 4EA representative example of a map generation control group 480 is shown. In the representative illustration, the map generation control group 480 is displayed on “Screen 5” of the GUI 400. The control group 480 preferably includes an image preview area 482, which may be similar to the area 416 described above, except that it optionally and preferably allows the user to mark points or regions 484 on the image. The control group 480 may also include a local feature selection control 486, which is shown as a slider in the exemplary illustration, but may also be embodied as any other type of selector. The control 486 allows the user to select the corresponding feature for each individual point 484. For example, when the control group 480 is used to generate a height map, the control 486 allows the user to select the height of the raised element for each individual point 484. The GUI 400 may have different control groups 480 for generating different maps, or it may display a map type selection control 488, allowing the user to select which feature to generate the map for. After the map type is selected, the label 490 of the control 486 changes accordingly. For example, in the example shown, a height map was selected, so label 490 represents "local height".

[0155] After activating the map creation control 492, the processor generates a corresponding map for all tiled elements on the tile pattern based on the local values ​​assigned to each point 484, for example, using an interpolation algorithm. In the case of non-numerical features (e.g., the shape of the tiled elements), the processor can utilize a proximity process to assign local values ​​to each feature based on its proximity to one or more points 484. Optionally and preferably, the created map is displayed in the image preview area 482, such as... Figure 4F As shown.

[0156] Figure 6 This is a flowchart illustrating a method suitable for generating computer object data for additive manufacturing according to some embodiments of the present invention. The additive manufacturing (e.g., printing) operation of this method is preferably performed by system 10 or 110. This method is useful where additive manufacturing involves three-dimensional printing on fabrics, and particularly useful where additive manufacturing involves three-dimensional inkjet printing on fabrics.

[0157] Computer programs implementing this method are typically distributed to users on distribution media, such as, but not limited to, flash memory, CD-ROM, or remote media that communicate with a local computer via the Internet. The computer program can be copied from the distribution media to a hard disk or similar intermediate storage medium. The computer program can be executed by loading computer instructions from its distribution media or intermediate storage medium into the computer's execution memory, configuring the computer to operate according to this method. All of these operations are well known to those skilled in the art of computer systems.

[0158] This method can be embodied in a variety of forms. For example, it can be embodied on a tangible medium, such as a computer for performing the method steps. It can be embodied on a computer-readable medium, including computer-readable instructions for performing the method steps. It can also be embodied in an electronic device with digital computing capabilities, which is arranged to run a computer program on a tangible medium or execute instructions on a computer-readable medium.

[0159] The method of this embodiment can be executed by a data processor (e.g., computer 24) operating an AM system. Computer object data processed by this method can be transmitted to the controller of the AM system (e.g., controller 20). The processed computer object data can be transmitted all at once before the AM process begins, or it can be transmitted in batches (e.g., piecewise transmission), wherein the AM process begins after the first batch arrives but before receiving the last batch. Alternatively, the method of this embodiment can be executed by the controller of the AM system (e.g., controller 20). In these embodiments, the controller receives input data and uses this input data to execute the method. The input data can be received by the controller before the AM process begins or in batches, wherein the AM process begins after the first batch arrives but before receiving the last batch.

[0160] The method begins at 600 and optionally and preferably continues to 601, where a GUI is displayed, such as, but not limited to, GUI 400. The method proceeds to 602, where image data describing the two-dimensional image selected by the GUI (e.g., via image selection control group 404) is loaded. In some embodiments of the invention, the method proceeds to 603, where, as described further in detail above, background and non-background regions are identified in the image.

[0161] The method proceeds to 604, where discrete tiling elements (e.g., element 422) are defined based on a tiling pattern (e.g., pattern 426) selected via a GUI (e.g., through tiling control group 420), as described in further detail above. Preferably, tiling is applied only to non-background areas of the image. The method optionally and preferably proceeds to 605, where one or more maps are generated that define local features of the raised elements forming the embossed pattern, as described in further detail above. Alternatively or additionally, the method may continue to 606, where features of the raised elements are selected non-locally. Preferably, operations 605 and 606 are applied to different features.

[0162] In some embodiments of the invention, the method proceeds to 607, where a GUI (e.g., via a lensing control group 460) selects a lensing scheme. Depending on the selected scheme, one or more features of the raised element (e.g., the color of the tiled element, the shape of the top of the raised element, and the transparency of the raised element) are preferably adjusted according to the lensing scheme.

[0163] The method proceeds to 608, where a three-dimensional image is displayed on the GUI, the image comprising discrete raised elements (e.g., raised element 450 of embossed pattern 458) protruding from tiling elements (e.g., element 422), as described in further detail above. The method proceeds to 609, where computer object data describing the raised elements is generated and stored in a computer storage device. The computer object data can be in any of the formats described above and can be generated by exporting a three-dimensional image of raised elements known in the art.

[0164] In some embodiments of the invention, the method proceeds to 609, where the computer object data is sliced ​​to provide slice data describing multiple slices, each slice defined on multiple voxels and describing a layer of the object to be manufactured. Slicing operation 609 preferably assigns construction material to each voxel of each slice based on the characteristics of the protrusion elements to intersect with the corresponding layer. The slice data can be generated by the same software operating the GUI, or by slicer software running independently of the GUI.

[0165] At 610, slice data describing the slices and the corresponding build material allocation is transmitted to the controller (e.g., controller 20) of the additive manufacturing system. The controller (e.g., controller 20) sends control signals to the AM system to manufacture layers corresponding to the slices. Preferably, the layer manufacturing is performed on a fabric, in which case the fabric is mounted on a tray (e.g., tray 12) of the AM system prior to the excitation operation 610.

[0166] The method ends at 611.

[0167] As used in this article, the term “about” means ± 10%.

[0168] The terms “including,” “contains,” “covers,” “includes,” and “have” mean “including but not limited to.”

[0169] The term "composed of" means "including and limited to".

[0170] The term "consistent primarily of" means that the composition, method, or structure may include additional ingredients, steps, and / or portions, provided that such additional ingredients, steps, and / or portions do not materially alter the basic and novel characteristics of the claimed composition, method, or structure.

[0171] As used herein, unless the context clearly specifies otherwise, the singular forms “a,” “an,” and “the” include plural references. For example, the terms “compound” or “at least one compound” can include a variety of compounds, including mixtures thereof.

[0172] In this application, various embodiments of the invention may be presented in a range format. It should be understood that the range format is merely for convenience and brevity and should not be construed as an inflexible limitation of the scope of the invention. Therefore, the description of a range should be considered as specifically disclosing all possible subranges and the individual values ​​within that range. For example, a description of a range such as 1 to 6 should be considered as specifically disclosing subranges such as 1 to 3, 1 to 4, 1 to 5, 2 to 4, 2 to 6, 3 to 6, etc., and the individual numbers within that range, such as 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

[0173] Whenever a range of numbers is indicated herein, it means to include any referenced numbers (fractions or integers) within the indicated range. The phrases “between” the first indicated number and the second indicated number, and “from” the first indicated number to the second indicated number, are used interchangeably herein and both refer to the first and second indicated numbers and all fractions and integers in between.

[0174] It should be understood that, for clarity, certain features of the invention described in the context of a single embodiment may also be provided in combination in a single embodiment. Conversely, for brevity, various features of the invention described in the context of a single embodiment may also be provided individually, or in any suitable sub-combination, or appropriately provided in any other described embodiment of the invention. Certain features described in the context of various embodiments should not be considered as essential features of those embodiments unless the embodiment is not functional without these elements.

[0175] Although the invention has been described in conjunction with specific embodiments thereof, it will be apparent to those skilled in the art that many alternatives, modifications, and variations will be apparent. Therefore, the invention is intended to cover all such alternatives, modifications, and variations falling within the spirit and broad scope of the appended claims.

[0176] The applicant intends that all publications, patents, and patent applications mentioned in this specification be incorporated herein by reference in their entirety, just as each individual publication, patent, or patent application is specifically and separately indicated to be incorporated herein by reference. Furthermore, any reference or identification of any reference in this application should not be construed as an admission that such reference is prior art to the invention. The use of section headings should not be construed as an inherent limitation. In addition, the entire contents of any priority document of this application are incorporated herein by reference.

Claims

1. A method for generating computer object data for additive manufacturing, the method comprising: Displays a graphical user interface (GUI) with image selection control group, tile selection control group, and embossed selection control group; Load image data describing the two-dimensional image selected by the image selection control group; Based on the tiling pattern selected by the tiling control group, a plurality of discrete tiling elements are defined, each of the plurality of discrete tiling elements being associated with a different portion of the image data; A 3D image is displayed on the GUI, the 3D image comprising a plurality of discrete raised elements respectively protruding from the tiled elements of the tiled pattern, wherein each raised element has a 3D shape selected by the emboss selection control group, and wherein at least one segment of each raised element has at least one intensity level according to a corresponding portion of the image data; and Generate computer object data describing the raised element, and store the computer object data in a computer storage device.

2. The method according to claim 1, comprising: Background and non-background regions are identified in the image, wherein the discrete tiling elements only tile the non-background regions.

3. The method according to any one of claims 1 and 2, wherein, The tile selection control group is configured to allow users to independently select the shape for the tiled elements and the spacing between the tiled elements.

4. The method according to any one of claims 1-3, wherein, The tile selection control group is configured to allow users to independently select the size of the tiled elements.

5. The method according to any one of claims 1-4, wherein, The tile selection control group is configured to allow users to select different sizes for different tiled elements.

6. The method according to any one of claims 1-5, wherein, The tile selection control group is configured to allow users to select different spacings between different pairs of tiled elements.

7. The method according to any one of claims 1-6, wherein, The emboss selection control group is configured to allow the user to select at least one of the following: (i) different heights for different embossed elements, (ii) different spacing between different pairs of embossed elements, and (iii) different cross-sectional dimensions for different embossed elements.

8. The method according to any one of claims 1-6, wherein, The emboss selection control group is configured to automatically select at least one of the following: (i) different heights for different raised elements, (ii) different spacing between different pairs of raised elements, and (iii) different cross-sectional dimensions for different raised elements.

9. The method according to any one of claims 1-8, wherein, The emboss selection control group is configured to select the height of the raised element based on the corresponding portion of the image data.

10. The method according to any one of claims 1-8, comprising: Load image data describing the additional image, wherein, for at least one raised element, the intensity levels of different segments of the raised element are based on the image data of different images.

11. The method according to any one of claims 1-10, wherein, The GUI includes a height map control group configured to generate or import height maps, wherein the emboss selection control group is configured to select the height of the raised element based on the height map.

12. The method according to any one of claims 1-11, wherein, The GUI includes a density map control group configured to generate or import density maps, wherein the emboss selection control group is configured to select the density of the raised element based on the density map.

13. The method according to any one of claims 1-12, wherein, The GUI includes a group of dimension map controls configured to generate or import dimension maps, wherein the emboss selection control group is configured to select the cross-sectional size of the raised element based on the dimension map.

14. The method according to any one of claims 1-13, wherein, The GUI includes a lensing control group configured to allow users to select a lensing scheme, wherein the shape, color, and transparency level of the raised element are selected based on the lensing scheme.

15. The method according to any one of claims 1-13, wherein, The GUI includes a lensing control group configured to allow the user to instruct the GUI to automatically select a lensing scheme, wherein the shape, color, and transparency level of the raised element are selected based on the lensing scheme.

16. The method according to any one of claims 1-15, comprising: The computer object data is sliced ​​into multiple slices, each slice is defined on multiple voxels, and the slices are stored in a computer storage device.

17. A computer software product comprising a computer-readable medium storing program instructions that, when read by a data processor, cause the data processor to perform the method according to any one of claims 1-16.

18. A method of additive manufacturing, comprising: Perform the method according to any one of claims 1-15; Load the computer object data from the computer storage device; The computer object data is sliced ​​into multiple slices, and each slice is defined on multiple voxels; For each voxel of each slice, construction material is allocated according to at least one intensity level of the corresponding protrusion element containing the voxel; as well as The multiple slices and corresponding building materials are distributed and transmitted to the controller of the additive manufacturing system for additive manufacturing of multiple layers corresponding to the multiple slices.

19. A method of additive manufacturing, comprising: Perform the method according to claim 16; Load the slice from the computer storage device; For each voxel of each slice, construction material is allocated according to at least one intensity level of the corresponding protrusion element containing the voxel; as well as The multiple slices and corresponding building materials are distributed and transmitted to the controller of the additive manufacturing system for additive manufacturing of multiple layers corresponding to the multiple slices.

20. The method according to any one of claims 18 and 19, comprising: The fabric is mounted on a tray of the additive manufacturing system so that the multiple layers are formed on the fabric by the system.

21. A system for generating computer object data for additive manufacturing, the system comprising a display device, a computer, and a computer storage device, wherein, The computer includes a processor configured to perform the method according to any one of claims 1-16.

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