A method for the digital design and manufacturing of elements for the production of a three-dimensional object, the installation enabling its implementation, and elements for the production of three-dimensional objects.

Abstract

Title: Digital design and manufacturing process for elements for the production of a three-dimensional object, the installation enabling its implementation, and elements for the production of three-dimensional objects. The digital design and manufacturing process for elements for the production of a three-dimensional object (1) obtained by the superposition and / or juxtaposition of layers (2) of particular perimeter shapes, consists of carrying out the following operations: for the design: choice of the object (1) to be reproduced, choice of the scale of reproduction of the object (1), choice of the sheet material (3) in which said layers (2) will be made, and recording of the thickness of said sheets (3), digitization of said object (1) to be manufactured, and digital decomposition by digital slicing into different complementary elementary layers, identification of each of the elements (2), distribution into sets (30) of said different elements (2), ,For manufacturing: printing identification codes on plates (3) of material conforming to that chosen, reproduction of the sets (30) on said plates (3) by cutting. Figure for the abbreviation: Fig. 2,

Description

Title of the invention: A method for the digital design and manufacture of elements for the production of a three-dimensional object, the installation enabling its implementation, and elements for the production of three-dimensional objects.

[0001] The present invention relates to a method for the digital design and manufacturing of elements for the production of three-dimensional objects, as well as the installation enabling its implementation, and to elements for the production of three-dimensional objects. The invention relates, without limitation, to the field of construction games, and uses the known concept of superimposing and / or juxtaposing layers of specific perimeter shapes to reproduce the object to be manufactured.

[0002] In the aforementioned recreational field, objects intended to be reconstituted by assembling pieces cut from a sheet of material are already known, and which constitute a kind of three-dimensional puzzle.

[0003] Some of these objects are made by assembling pieces that are perpendicular to others, by half-lap joints, which allows volume to be created using little raw material, but with a result that is too "skeletal", which is not suitable for all the shapes that one wishes to reproduce.

[0004] Others are made by superimposing layers, with indexing and securing by an edge of each layer on a support, which limits the reproducible shapes.

[0005] Finally, objects are known that consist of superimposed layers cut from a flat material and assembled by being threaded onto at least one rigid insert attached to a base and positioned perpendicular to the planes of said layers. Preferably, more than one insert is used to obtain better indexing while avoiding the risk of pivoting.

[0006] As regards the design and manufacture of the elements intended for the realization of these objects, this consists of breaking down the different elementary layers, cutting or pre-cutting them from sheets of material, and packaging them.

[0007] For objects comprising one or more inserts, the process includes an additional step of drilling each of the elements for the passage of an insert.

[0008] Known manufacturing processes are very limited with regard to the choice of objects to be designed, as well as the size of these objects.

[0009] The present invention aims to overcome this drawback by proposing a method for the digital design and manufacturing of a three-dimensional object obtained by the superposition and / or juxtaposition of layers of specific perimetric shapes of the object to be manufactured, going so far as to allow for custom manufacturing. will.

[0010] The method for the digital design and manufacturing of elements for the production of a three-dimensional object obtained by the superposition and / or juxtaposition of layers of particular perimeter shapes of the object to be manufactured, is characterized in that it consists of carrying out the following operations:

[0011] for design through a digital chain enabling: - choice of the object to reproduce, - choice of the object's reproduction scale - selection of the sheet material in which the said layers will be made, and survey of the thickness of the said plate(s), - digitization of said object to be manufactured or import of a file in a suitable format, and digital decomposition thereof and digital slicing into different complementary elementary layers, of a thickness corresponding to that of said plate(s), - identification of each element corresponding to a layer or stratum, - distribution into at least a range of said different elements, optimization of said distribution according to the dimensions of the said plate(s), their packaging, and their orientation, for manufacturing: - printing of identification codes on at least one plate of material conforming to the chosen material, - reproduction of the set(s) on the said plate(s) by cutting,

[0012] The design and manufacturing process according to the invention makes it possible, from an order carried out virtually, to design and manufacture an object to be reconstituted, by optimizing the quantity of material used.

[0013] The design and manufacturing process according to the invention can have many variations.

[0014] Thus, advantageously, during the optimization operation of distribution into panoply, the sizing of the plates is incorporated in accordance with the size of the packaging intended for the shipping packaging of said plates.

[0015] According to one variant, during the optimization operation of the distribution into sets, knowing that there is an existing package whose dimensions and storage capacity are known, the final dimensions of the object to be reconstituted and therefore those of the set or sets are adjusted so as to be able to fit the set or sets into said packaging.

[0016] According to another embodiment, during the panoply distribution optimization operation, the dimensions of each of the plates are determined simultaneously, as well as the characteristics and dimensions of the packaging intended for the packaging. shipping of said plates, while during the manufacturing operation, said packaging is also carried out.

[0017] According to an additional feature of the process according to the invention, during the optimization operation of distribution in panoply, according to the dimensions of panels in which the plates are to be cut, sub-assemblies are created, each grouping a certain number of plates, so as to allow optimized management of the material used, both at the level of said plates and at that of said panels.

[0018] It should be noted that the manufacturing operation may include the printing of assembly instructions.

[0019] Also advantageously, the design operation includes, after the digital decomposition of the object, a step of choosing the use of at least one guide insert, determining the nature of the insert, and determining the location of a hole for the passage of said insert for each of the elements intended to be traversed by an insert, while during the manufacturing operation, the cutting of the sets is completed by cutting the passage locations.

[0020] According to a particularly advantageous variant, during the design operation, when choosing to use at least one insert, the production of said insert is designed from the partial cutting of an element, intended to be partially detached and straightened to be engaged in a passage of the adjacent element, and possibly in the following element(s), while during the manufacturing operation, the said insert(s), as well as the associated passage(s), are created by a partial cutting.

[0021] According to an additional feature, several inserts are designed in the same element and / or in elements arranged at different levels.

[0022] According to another additional feature, inserts are designed which, although originating from different elements, pass through the same elements.

[0023] According to another additional feature, when choosing the material, its colour is also determined and chosen.

[0024] According to another additional feature, the plates consist of corrugated cardboard.

[0025] In this regard, it should be noted that during the design process, the orientation of the grooves is taken into account when assembling the assembly. Indeed, this is important not only from an aesthetic point of view, but also in the case of the creation of at least one insert, whose two parallel cutouts should preferably, for the purpose of rigidity, be parallel to said grooves.

[0026] According to another additional feature, a digitally designed color application operation on the layers, according to a color identification code usable for the assembly operation, or to identify the final object on a visible layer by dedication or by a color logo.

[0027] According to another additional feature, a color deposition operation is designed digitally on the strata, at least on their peripheral edge on the portion intended not to be covered by the adjacent stratum, and / or on the edge, and then this color deposition is carried out.

[0028] The present invention also relates to an installation enabling the implementation of the process of designing and manufacturing three-dimensional objects; it is characterized in that it comprises means for digitizing the object to be reproduced, computer means associated with one or more software programs for the digital decomposition of said object by digital slicing into different complementary elementary layers, means for putting into a set, means for transmitting data to printing means and cutting means.

[0029] The installation according to the invention is advantageously complemented by robotic means of packaging in a shipping container.

[0030] The present invention also relates to elements for manufacturing a three-dimensional object designed by superimposing and / or juxtaposing layers of particular perimeter shapes, which elements constitute said layers, while at least one of said layers comprises a partially detachable part, capable of being folded to protrude from said layer, while at least the adjacent layer intended to be immediately superimposed has an opening intended to allow the narrow passage of said detachable part for the purpose of indexing the relative positioning of said layers and immobilizing one with respect to the other.

[0031] The advantages and characteristics of the process according to the invention will become clearer from the following description, which relates to the attached drawing, which represents a non-limiting embodiment thereof.

[0032] In the attached drawing:

[0033] [Fig-1] represents a perspective view of a three-dimensional object made with elements obtained by the design and manufacturing process according to the invention,

[0034] [Fig.2] represents a plan view of the elements obtained by the same process for the realization of the same object,

[0035] [Fig.3] represents a perspective view of a stage in the realization of the same object,

[0036] [Fig.4] represents a perspective view of another stage in the realization of the same object.

[0037] With reference to [Fig. 1], a three-dimensional object 1 can be seen, representing, in this case, but not limited to, a dog's head. It can be observed that this object 1 is obtained by layering elements 2 with perimeter contours by particulars. The elements 2 consist, in this non-limiting example, of parts of corrugated cardboard sheets 3, previously cut respecting the digital decomposition of the original object, the direction of the flutes 31, and its digital slicing into different complementary elementary layers, through a known process.

[0038] Fig. 1 represents the object that can be constructed from the elements 2 designed and manufactured using the process according to the invention.

[0039] The method according to the invention makes it possible, starting from a chosen original object, to create and manufacture the elements 2 necessary to reconstruct it. The method comprises digitizing the original object or importing a three-dimensional CAD file, in a suitable format, relating to that object.

[0040] The aim being to offer, but not limited to, a fun construction activity, the design and manufacturing process according to the invention includes, in addition to the manufacture of the elements 2, their organization into sets and the optimized packaging of these in a package ready for shipment and / or sale.

[0041] Thus, the process according to the invention allows several manufacturing options, including among others the choice of materials, the choice of colours and the choice of the reproduction scale.

[0042] With reference to [Fig.2], we can see a multiplicity of plates 3, each comprising a set 30, corresponding to the set of elements 2 allowing the object 1 to be reconstituted. These elements 2 are pre-cut, so that they can be detached from the plates 3.

[0043] It will be noted that this [Fig.2] can also consist of the representation of the sets created during the design operation, upstream of the manufacturing operation.

[0044] All the plates 3 are of the same dimensions; they are intended to be stacked and then packaged in a container, not shown. The dimensions of the plates 3 are determined based on those of the container, if one exists, or in an optimized manner in conjunction with a packaging creation operation.

[0045] The assembly during the design phase is carried out in such a way as to optimize the quantity of material used, and more particularly the number of plates 3 required.

[0046] It should be noted that it is possible to create subsets each grouping a certain number of plates 3, allowing optimized management at two levels, that of the plates 3 and that of the panels from which the plates 3 originate.

[0047] In addition to their particular peripheral contour, it can be observed that most of the elements 2 have internal full cutouts 20 or partial cutouts 21. The full cutouts 20 define, but are not limited to, slots 22 with a width at least equal to, but preferably, to avoid gaps, equal to the thickness of the plate 3, while the partial cutouts 21 define tabs 23 of a width at most equal, but preferably, to avoid play, equal to the length of the slots 20, partially detachable from the plate 2 and straightenable by folding, in order to constitute a guide insert.

[0048] It should be noted that, preferably, the tabs 23 have at their base, i.e. at the level of the ends of the cutting lines, a transverse groove 24 intended to mark and facilitate folding to form the insert.

[0049] With reference also to figures 3 and 4, the method of use of the slots 22 and the tabs 23 can be seen in detail.

[0050] On [Fig.3], we can see a stack 4 of a number of elements 2, the last of which has two tabs 23 resulting from partial cuts 21, in the process of being straightened.

[0051] On [Fig.4], it can be seen that an additional element 2 has been placed on the stack 4, that this element 2 has two total cutouts 20 creating two slots 22, into each of which is threaded a tab 23 from the element 2 which has just been covered.

[0052] It will be understood that the tabs 23 serve, on the one hand, to create a framework perpendicular to the layers, and on the other hand, to contribute to the perfect positioning of the elements 2 relative to each other. Indeed, while identification codes for the elements 2 may have been initially printed on the plates 3 to indicate the stacking order, this is not sufficient for the correct indexing of the elements relative to each other.

[0053] It will be noted on [Fig.3] that the upper element 2 of the stack 4 also has slots 22 in which tabs 23 from an element 2 of the stack 4 are engaged and protrude.

[0054] According to an unrepresented variant, it is possible to provide that elements 2 are crossed by tabs 23 from different elements 2, so as not to create a break in the reinforcement.

[0055] The positions of the cuts 20 and 21 are of course determined during the digital decomposition and slicing. During this operation, if the material used is corrugated cardboard, the direction of the flutes 31 is taken into account for the orientation of the partial cuts 21.

[0056] According to one variant, each of the elements is drilled with several holes, preferably at least two, intended to be passed through by rigid inserts, made of wood or other materials, supplied with the plates 3.

[0057] In its most common version, namely that the plates 3 are made of corrugated cardboard, during the construction of object 1 the plates 3 are joined together by gluing. Therefore, the kits will be packaged with a container of glue such as a tube, and it During the design and manufacture of the 30 sets, a space will be reserved to accommodate this container.

[0058] In a version including added inserts, one or more spaces will be provided in the same way to accommodate these inserts.

[0059] As regards the cutting operation, it can be carried out in different ways.

[0060] By way of limitation, a cutter cutting machine, comprising a vibrating knife cutting head, which travels through the sets, can be used.

[0061] In the case of large series for example, a machine equipped with cutting means can also be used, allowing the entire set to be cut in one pressing.

Claims

Demands

1. A method for the digital design and manufacturing of elements for the production of a three-dimensional object (1) obtained by the superposition and / or juxtaposition of layers (2) of specific perimeter shapes of the object (1) to be manufactured, characterized in that it consists of performing the following operations: for the design through a digital chain enabling: - choice of the object (1) to reproduce, - choice of the object reproduction scale (1), - choice of the sheet material (3) in which will be made said strata (2), and measurement of the thickness of said plates (3), - digitization of said object (1) to be manufactured or import of a file of suitable format, and digital decomposition thereof and digital slicing into different complementary elementary layers, of thickness corresponding to that of said plates (3), - a step of selecting the use of at least one guide insert (23), determining the nature of the insert (23), and determining the location of a hole (22) for the passage of said insert (23) for each of the elements (2) intended to be traversed by an insert (23), which is designed from the partial cutting of an element (2), and intended to be partially detached from it and straightened to be engaged in a passage (22) of the adjacent element (2), and possibly in the following element(s) (2), - identification of each of the elements (2) corresponding to a layer or stratum, - distribution into sets (30) of said different elements (2), optimization of said distribution according to the dimensions of said plates (3), and their packaging, for manufacturing: - printing of identification codes on plates (3) of material conforming to that chosen, - reproduction of the sets (30) on the said plates (3) by cutting, including partial cutting of said insert(s) (23), as well as of associated passage(s) (22).

2. A design and manufacturing method according to claim 1, characterized in that during the optimization operation of distribution into sets (30), knowing that an existing package is available whose dimensions and storage capacity are known, the final dimensions of the object (1) to be reconstituted and therefore those of the set(s) (30) are adjusted so as to be able to package the set(s) (30) in said packaging.

3. A design and manufacturing method according to claim 1, characterized in that during the panoply distribution optimization operation (30), the sizing of the plates (3) is incorporated in accordance with the size of the packaging intended for the shipping packaging of said plates (3).

4. A design and manufacturing method according to claim 3, characterized in that during the panoply distribution optimization operation, (30) the dimensions of each of the plates (3) are simultaneously determined, as well as the characteristics and dimensions of the packaging intended for the shipping packaging of said plates (3), while during the manufacturing operation, said packaging is also produced.

5. A design and manufacturing method according to any one of claims 1 to 4, characterized in that during the optimization operation of distribution into a set (30), according to the dimensions of the panels in which the plates (3) are to be cut, sub-assemblies are created, each grouping a certain number of plates (3), so as to allow optimized management of the material used, both at the level of said plates (3) and at that of said panels.

6. A method of designing and manufacturing according to any one of claims 1 to 5, characterized in that several inserts (23) are designed in the same element (2) and / or in elements (2) arranged at different levels.

7. A method of design and manufacture according to claim 6, characterized in that inserts (23) are designed which, although originating from different elements (2), pass through the same elements (2).

8. A method of designing and manufacturing according to any one of claims 1 to 7, characterized in that when choosing the material, the color of the material is also determined and chosen.

9. A method of designing and manufacturing according to any one of claims 1 to 8, characterized in that the plates (3) consist of corrugated cardboard.

10. A design and manufacturing method according to claim 9, characterized in that during the design operation, the orientation of the flutes (31) of the corrugated cardboard is taken into account during the assembly (30).

11. A method of designing and manufacturing according to any one of claims 1 to 10, characterized in that a color deposition operation on the elements (2) is designed digitally, according to a color identification code usable for the assembly operation.

12. A method of designing and manufacturing according to any one of claims 1 to 11, characterized in that a color deposition operation is digitally designed on the elements (2), at least on their peripheral edge on the portion intended not to be covered by the adjacent element (2), and / or on the edge, and then this color deposition is carried out.

13. Installation enabling the implementation of the process of designing and manufacturing three-dimensional objects according to any one of claims 1 to 12, characterized in that it comprises means for digitizing the object to be reproduced, computer means associated with one or more software programs for digitally decomposing said object by digital slicing into different complementary elementary layers, means for putting into a set, means for transmitting data to printing means and cutting means.

14. Installation according to claim 13, characterized in that it also includes robotic means for packaging in a shipping package.

15. Elements for manufacturing a three-dimensional object designed by superimposing and / or juxtaposing layers of particular perimeter shapes, and resulting from the digital design and manufacturing process according to any one of claims 1 to 12, characterized in that they constitute said layers (2), and in that at least one of said layers (2) comprises a partially detachable part (23) capable of being folded to protrude from said layer (2), while at least the adjacent layer (2) intended to be immediately superimposed has an opening (22) intended to allow the narrow passage of said detachable part (23) for the purpose of indexing the relative positioning of said layers (2) and immobilizing one with respect to the other.

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