Support design device, support design method, and program

Abstract

To design appropriately a support to suppress deformation of a molded object.SOLUTION: A support design device for designing a support that is integrally molded with a molded object in order to suppress deformation of the molded object molded by additive manufacturing includes: a design model acquisition part that acquires a design model representing the molded object; a support design area setting part that sets a support design area, which is an area where the support is added to the design model; a deformation amount analysis part that continuously changes parameters that define support specifications and calculates multiple deformation amounts, which are the magnitude of deviation from the design model of the molded object when the supports are added within the support design area; and a support design part that outputs parameters that satisfy a reference value and minimize an amount of the support when the deformation amount analysis part calculates the deformation amount that satisfies the predetermined reference value.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a support design device, a support design method, and a program. [Background technology]

[0002] Patent Document 1 describes a modeling data creation device that predicts warpage during AM (Additive Manufacturing) modeling by deformation analysis and then arranges support structures to keep the amount of warpage within a tolerance. The modeling data creation device described in Patent Document 1 derives a shape of a support structure (type of support structure) that keeps the deformation of the main body of the model within a tolerance based on the allowable deformation amount of the main body of the model and the calculated out-of-plane deformation amount for each layer.

[0003] Patent Document 2 also describes the following computing device. That is, in AM, there are cases where the required shape accuracy of the product cannot be obtained due to thermal deformation that occurs during modeling. Therefore, the computing device described in Patent Document 2 predicts the amount of deformation in advance using modeling deformation analysis, and applies deformation in the opposite direction to the model to ensure excellent shape accuracy after modeling. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2021-94698 [Patent Document 2] Patent No. 7123278 Summary of the Invention [Problem to be solved by the invention]

[0005] However, Patent Document 1 does not show which shape to select from among multiple shapes of the support structure that can keep the deformation of the main body of the object within an allowable range. Therefore, in such a case, it may be impossible to select an appropriate shape, and it may not be possible to design the support appropriately.

[0006] The present disclosure has been made in consideration of the above circumstances, and aims to provide a support design device, a support design method, and a program that are capable of appropriately designing supports to suppress deformation of a structure. [Means for solving the problem]

[0007] In order to solve the above problems, a support design device according to the present disclosure is a device for designing supports that are formed integrally with an object formed by additive manufacturing in order to suppress deformation of the object, and includes a design model acquisition unit that acquires a design model representing the object, a support design area setting unit that sets a support design area, which is an area where the supports are added to the design model, a deformation amount analysis unit that continuously changes parameters that define the specifications of the supports, and calculates multiple deformation amounts, which are the magnitude of deviation of the object from the design model when the supports are added within the support design area, and a support design unit that, when the deformation amount analysis unit calculates the deformation amount that satisfies a predetermined reference value, outputs the parameters that satisfy the reference value and minimize the amount of the support.

[0008] A support design method according to the present disclosure is a method for designing supports that are formed integrally with an object formed by additive manufacturing in order to suppress deformation of the object, and includes the steps of obtaining a design model representing the object, setting a support design area in the design model where the supports are added, continuously changing parameters that define the specifications of the supports, and calculating multiple deformation amounts, which are the magnitude of deviation of the object from the design model when the supports are added within the support design area, and, when the calculated deformation amount satisfies a predetermined reference value, outputting the parameters that satisfy the reference value and minimize the amount of support.

[0009] A program according to the present disclosure is a program for designing supports that are formed integrally with an object formed by additive manufacturing in order to suppress deformation of the object, and causes a computer to execute the following steps: obtaining a design model representing the object; setting a support design area in the design model where the supports are added; continuously changing parameters that define the specifications of the supports, and calculating multiple deformation amounts, which are the magnitude of deviation of the object from the design model when the supports are added within the support design area; and, when the calculated deformation amount satisfies a predetermined reference value, outputting the parameters that satisfy the reference value and minimize the amount of support. Effect of the Invention

[0010] According to the support design device, support design method, and program disclosed herein, it is possible to appropriately design supports for suppressing deformation of a molded object. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a schematic block diagram of an additive manufacturing system according to an embodiment of the present disclosure. [Diagram 2]FIG. 1 is a schematic block diagram of a support design apparatus according to an embodiment of the present disclosure. [Diagram 3] FIG. 2 is a front cross-sectional view illustrating a schematic diagram of an example of a design model according to an embodiment of the present disclosure. [Figure 4] FIG. 1 is a perspective view illustrating a schematic example of a design model according to an embodiment of the present disclosure. [Diagram 5] FIG. 1 is a schematic diagram illustrating an example of a shaped object for explaining an embodiment of the present disclosure. [Figure 6] FIG. 2 is a front cross-sectional view illustrating a schematic diagram of an example of a design model according to an embodiment of the present disclosure. [Figure 7] 11A to 11C are diagrams illustrating an example of a correlation between a molding deformation amount and an actual measurement value of shape accuracy based on a molding result after inverse distortion correction according to an embodiment of the present disclosure. [Figure 8] FIG. 1 is a perspective view illustrating an example of a molded object for explaining an embodiment of the present disclosure. [Figure 9] FIG. 1 is a perspective view illustrating an example of a molded object for explaining an embodiment of the present disclosure. [Figure 10] FIG. 2 is a front cross-sectional view illustrating a schematic diagram of an example of a design model according to an embodiment of the present disclosure. [Figure 11] FIG. 1 is a perspective view illustrating a schematic example of a design model according to an embodiment of the present disclosure. [Figure 12] FIG. 1 is a schematic diagram for explaining an embodiment of the present disclosure. [Figure 13] FIG. 1 is a perspective view illustrating a schematic example of a design model according to an embodiment of the present disclosure. [Figure 14] 11 is a flowchart for explaining an example of the operation of the support design device according to the embodiment of the present disclosure. [Figure 15] 11 is a flowchart for explaining an example of the operation of the support design device according to the embodiment of the present disclosure. [Figure 16] FIG. 1 is a schematic block diagram illustrating a configuration of a computer according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] A support design device, a support design method, and a program according to an embodiment of the present disclosure will be described below with reference to FIGS. 1 to 16. FIG. 1 is a schematic block diagram of an additive manufacturing system according to an embodiment of the present disclosure. FIG. 2 is a schematic block diagram of a support design device according to an embodiment of the present disclosure. FIG. 3 is a front cross-sectional view that shows a schematic example of a design model according to an embodiment of the present disclosure. FIG. 4 is a perspective view that shows a schematic example of a design model according to an embodiment of the present disclosure. FIG. 5 is a schematic view that shows an example of a molded object for explaining an embodiment of the present disclosure. FIG. 6 is a front cross-sectional view that shows a schematic example of a design model according to an embodiment of the present disclosure. FIG. 7 is a diagram showing an example of a correlation between a molding deformation amount according to an embodiment of the present disclosure and an actual measurement value of shape accuracy based on a molding result after inverse distortion correction. FIG. 8 and FIG. 9 are perspective views that show an example of a molded object for explaining an embodiment of the present disclosure. FIG. 10 is a front cross-sectional view that shows a schematic example of a design model according to an embodiment of the present disclosure. FIG. 11 is a perspective view that shows a schematic example of a design model according to an embodiment of the present disclosure. FIG. 12 is a schematic view that shows an embodiment of the present disclosure. Fig. 13 is a perspective view showing an example of a design model according to an embodiment of the present disclosure. Fig. 14 and Fig. 15 are flow charts for explaining an example of the operation of a support design device according to an embodiment of the present disclosure. Fig. 16 is a schematic block diagram showing a configuration of a computer according to an embodiment of the present disclosure. Note that in each figure, the same or corresponding configurations are designated by the same reference numerals and the description is omitted as appropriate.

[0013] (Modeling System) Fig. 1 shows a configuration example of an additive manufacturing system according to an embodiment of the present disclosure. Fig. 2 shows a configuration example of a support design device according to an embodiment of the present disclosure. As shown in Fig. 1, an additive manufacturing system 1 according to an embodiment of the present disclosure includes a modeling device 2, a measuring device 3, and a support design device 4.

[0014] (modeling equipment) The modeling device 2 is a device for modeling a shaped object by additive manufacturing. As shown in FIG. 3 and FIG. 4, the shaped object 50 is a member having a predetermined three-dimensional shape, and the material and shape of the shaped object 50 may be arbitrary. FIG. 3 and FIG. 4 show a three-dimensional design model 5 representing the shaped object 50 and a base plate 6 serving as a base on which material powder is spread during additive manufacturing. The relationship between the directions of the figures is shown in the XYZ directions as appropriate. In this case, the shaped object 50 includes a cylindrical portion 51, a top plate portion 52, and a cylindrical portion 53. The design model 5 includes, for example, the shaped object 50 and a scaffolding support 54. The shaped object 50 is a combination of materials forming a functional element, and constitutes all or a part of the target product. The scaffolding support 54 is a support for suppressing deformation in the Z direction to prevent recoater interference due to warpage deformation in the Z direction caused by solidification and shrinkage of the material. The scaffolding support 54 is a member that is not included in the target product and is ultimately separated from the model 50. For example, as shown in FIG. 5, the scaffolding support 54 is provided for the model 70 when the model 70 includes an overhanging member 72 that is supported at an angle θ=0 to 45 degrees with respect to a member 71 stacked in the Z direction and does not have a stacked portion that overlaps with the member 71 below in the Z direction. The model 50 does not include the scaffolding support 54 depending on the shape. The model 50 includes multiple scaffolding supports 54 depending on the shape. The scaffolding support 54 is one configuration example of the "second support that suppresses deformation in the stacking direction of the model" according to the present disclosure. The scaffolding support 54 (second support) can have a lower rigidity than the support 7a described later in a direction perpendicular to the stacking direction. This is a relative difference resulting from the support 7a described later being a support for mainly suppressing deformation in a direction perpendicular to the stacking direction.

[0015] The modeling device 2 is a device that materializes a model by stacking modeling layers by combining materials based on a design model 5. The modeling device 2 manufactures a model 50 of a desired three-dimensional shape by stacking multiple layers. The three-dimensional stacking method by the modeling device 2 may be any method, and for example, an additive manufacturing process that selectively melts and solidifies a powder bed using thermal energy such as powder bed fusion (PBF) can be used. In this case, the modeling device 2, for example, irradiates a bed of powder with light such as a laser beam to harden the irradiated part to form a layer, moves the bed in the stacking direction, and repeats the same process to form a model. In addition, for example, the modeling device 2 may form a model by repeatedly irradiating a heat source such as a laser beam on the sprayed powder to form a molten pool, adding a molten material such as a powder or wire into the molten pool to melt and solidify it, and forming a build-up layer on the layer, and repeating the process of irradiating the heat source and adding a molten material on the layer to form a build-up layer. Hereinafter, the direction in which the layers are stacked, that is, the stacking direction, will be referred to as the Z direction.

[0016] In this embodiment, the modeling apparatus 2 models the object 50 based on the design model 5 that represents the target shape of the object 50. That is, the modeling apparatus 2 models the object 50 by stacking layers to form the target shape based on information on the design model 5 that represents the target shape. The object 50 modeled by the modeling apparatus 2 is modeled to have the target shape, but may deform due to, for example, thermal contraction, resulting in a shape that deviates from the target shape. In this embodiment, the amount of deviation of the object 50 from the target shape (design model 5) is referred to as the modeling deformation amount (or modeling amount). FIG. 6 shows an example of the object 50 in a deformed state.

[0017] (Measuring Equipment) The measuring device 3 is a device that measures the shape of the manufactured object 50. The measuring device 3 may measure any position of the manufactured object 50, but in this embodiment, it measures the shape of the surface of the object. The measuring device 3 may measure the entire surface of the object 50, or may measure a part of the entire surface. When measuring a part of the entire surface of the object 50, it is more preferable that the measuring device 3 measures the shape of one surface of the object 50 from an end point (bottom) on the opposite side to the Z direction to an end point (tip) on the Z direction side. In addition, when the object 50 is not composed of one continuous member without interruption but is composed of multiple members separated from each other, it is preferable that the measuring device 3 measures the surface shape of each of those members.

[0018] The measuring device 3 calculates the amount of deviation of the measured shape of the object 50 from the target shape as the actual deformation amount. The actual deformation amount can be said to be the amount of deviation of the actual shape of the surface of the object 50 from the target shape. The measuring device 3 calculates the actual deformation amount for each position on the surface of the object 50 where the shape is measured. That is, in this embodiment, the measuring device 3 calculates the actual deformation amount for each position from the end point on the opposite side in the Z direction to the end point on the Z direction side of the surface of the object 50.

[0019] (Support design device) The support design device 4 is a device for designing supports that are formed integrally with a model to suppress deformation of the model formed by additive manufacturing, and can be configured using one or more computers such as a server or a personal computer. Note that some or all of the computers constituting the support design device 4 may be virtually configured on a network. The support design device 4 also includes the following units as a functional configuration configured by a combination of hardware such as a computer and peripheral devices constituting the support design device 4 and software such as a program executed by the computer. That is, the support design device 4 includes, as a functional configuration, a design model acquisition unit 101, a shape measurement data acquisition unit 102, a modeling deformation amount analysis unit 103, a correlation information database 104, a reference value setting unit 105, a support design area setting unit 106, a support design unit 107, a support shape setting unit 108, a modeling deformation amount analysis adjustment unit 109, an inverse distortion correction setting unit 110, and a CAD (Computer Aided Design) data output unit 111, as shown in FIG. 2.

[0020] The design model acquisition unit 101 acquires data indicating a design model 5 representing a molded object 50 as shown in Figures 3 and 4, which has been created using an external computer, for example, via a wired or wireless communication line or a recording medium in response to a user's instruction operation.

[0021] The shape measurement data acquisition unit 102 acquires data measured by the measurement device 3 via a wired or wireless communication line or a recording medium in response to an instruction operation by a user.

[0022] The modeling deformation amount analysis unit 103 performs an analysis based on the design model 5 based on the finite element method using a known inherent strain method as described in Patent Document 2, for example, and estimates the modeling deformation amount. The modeling deformation amount analysis unit 103 performs an analysis of the modeled object 50 based on a target shape based on the design model 5 and a reference inherent strain value, and estimates the modeling deformation amount, which is the deviation amount of the shape of the modeled object 50 from the target shape in the analysis. The modeling deformation amount analysis unit 103 sets an inherent strain value of the modeled object 50 in the analysis based on the reference inherent strain value, and estimates the modeling deformation amount of the model of the modeled object 50 that is the target shape using the set inherent strain value as a parameter in the analysis (hereinafter also referred to as an analysis parameter). The modeling deformation amount analysis unit 103 applies the reference inherent strain value to the model of the modeled object 50 in the target shape in the analysis, thereby simulating the deformation of the modeled object 50 and calculating the modeling deformation amount. The reference inherent strain value refers to an inherent strain value that is used in the analysis as a reference for the inherent strain value of the object 50. The reference inherent strain value may be an arbitrarily set value, and for example, a value that is set in advance based on the material of the object 50, regardless of the shape of the object 50, may be used.

[0023] In this embodiment, the modeling deformation amount analysis unit 103 calculates, for example, the modeling deformation amount based on the design model 5 in the absence of the support 7a described below, or calculates multiple deformation amounts, which are the magnitude of deviation of the model 50 from the design model 5 when the support 7a is added within the support design area 7 by continuously changing parameters that define the specifications of the support 7a, as described below.

[0024] The correlation information database 104 stores correlation information, which is data representing the correlation between the estimated modeling deformation amount and the actual measurement value of the shape accuracy based on the modeling result after the inverse distortion correction. As described in Patent Document 2, the inverse distortion correction is a correction that deforms the design model 5 in a direction opposite to the predicted deformation. By performing the inverse distortion correction on the design model 5, the deformation amount caused by modeling can be suppressed. FIG. 7 shows an example of a correlation line (regression line) representing the correlation information. In FIG. 7, the horizontal axis represents the modeling deformation amount estimated based on a design model of a predetermined test piece before the inverse distortion correction is performed, and the vertical axis represents the actual measurement value of the shape accuracy measured on a test piece that is modeled based on a design model in which the inverse distortion correction is performed on the design model of the test piece. The shape accuracy is, for example, a statistic (maximum value, average value, etc.) of the measurement value of the modeling deformation amount. Based on the correlation line represented by the correlation information, the shape accuracy after the inverse distortion correction can be estimated from the modeling deformation amount estimated by the analysis. In the example shown in FIG. 7, if the target accuracy of the molded object 50 is 0.2 mm, if the molding deformation amount estimated based on the design model 5 before performing the inverse distortion correction is within 0.4 mm, it is estimated that the target accuracy of 0.2 mm can be achieved by performing the inverse distortion correction. In this case, the reference value for determining whether or not to install supports is 0.4 mm, which is the value of the molding deformation amount by analysis. For example, as illustrated in FIG. 6, if the molding deformation amount by the analysis before performing the inverse distortion correction is 0.6 mm, the shape accuracy after the inverse distortion correction is 0.3 mm, which is estimated not to satisfy the target accuracy of 0.2 mm. Note that, for example, a plurality of measurement points (estimated points) of the reference value, the target accuracy, the shape accuracy, and the molding deformation amount can be set for one molded object 50, but the following description will be simplified assuming that there is only one of each.

[0025] It is desirable to prepare multiple pieces of correlation information, for example, for each shape, each material, and each deformation mode exemplified in Fig. 8 and Fig. 9. Fig. 8 shows an example in which step deformation has occurred in a shaped object 73. Fig. 9 shows an example in which bending deformation has occurred in a shaped object 74.

[0026] The reference value setting unit 105 refers to the correlation information stored in the correlation information database 104, and sets a reference value corresponding to the molding deformation amount based on the design model 5 before inverse distortion correction is performed in order to satisfy the target accuracy for the molded object 50. In this case, the reference value is a value assuming that inverse distortion correction, which is a correction that deforms the design model 5 in the direction opposite to the predicted deformation, will be performed. In addition, the reference value setting unit 105 compares the set reference value with the molding deformation amount calculated by the molding deformation amount analysis unit 103, determines whether the molding deformation amount is equal to or less than the reference value, and if the molding deformation amount is equal to or less than the reference value, decides not to install supports.

[0027] For example, when the estimated modeling deformation amount does not satisfy the reference value set by the reference value setting unit 105, the support design area setting unit 106 sets a support design area, which is an area where support is added to the design model 5, according to, for example, a user's instruction operation or automatically based on a plurality of setting methods prepared in advance. Fig. 10 and Fig. 11 show an example of a support design area 7 set for the design model 5. Fig. 13 shows an example in which a support 7a is added to the design model 5.

[0028] The support design area 7 is a design area of ​​supports 7a that are formed integrally with the object 50 in order to suppress deformation of the object 50 formed by additive manufacturing, and is a three-dimensional area set for the object 50 on the three-dimensional model. The support 7a is set by the support design device 4 (support shape setting unit 108) so as to have a shape corresponding to a part or all of the area in the support design area 7. The support design area 7 can be set, for example, for a portion that does not satisfy the target accuracy. The support design area 7 can be set in a distributed manner at a plurality of portions for the object 50, or can have an arbitrary shape. The support 7a is a support for suppressing deformation in, for example, the XY direction. In addition, the support 7a often has a relatively high rigidity for the purpose of suppressing deformation in the XY direction, while the scaffolding support 54 for the purpose of suppressing deformation in the Z direction has a relatively low rigidity. In addition, the support design area 7 can change the suppression force or suppression effect against deformation by the design area parameters. The design area parameters are parameters that define the specifications of the support 7a. The design region parameter can be, for example, a value representing the equivalent stiffness of the support design region 7 (also referred to as the support equivalent stiffness), a value representing the plate thickness when the support design region 7 has a plate-shaped region, or the like. The value representing the equivalent stiffness of the support design region 7 is, for example, expressed as a value of 0 to 100%, and is a value when the stiffness of the support 7a formed in the support design region 7 is equivalently expressed as the stiffness of the entire support design region 7. For example, when the equivalent stiffness is 100%, the entire region of the support design region 7 is formed as the support 7a. For example, when the equivalent stiffness is 50%, the support 7a having a volume (or mass) half the volume (or mass) of the entire support design region 7 is formed. Alternatively, for example, when the equivalent stiffness is 50%, the support 7a is formed so that it has the outer shape of the entire support design region 7 and half of the volume is a hole. Also, for example, when the equivalent stiffness is 0%, the support 7a is not formed. The design domain parameters may include multiple variables, such as a value representing an equivalent stiffness and a dimension, or may include one variable, such as only a value representing an equivalent stiffness or only a dimension.

[0029] When the molding deformation amount analysis unit 103 calculates a molding deformation amount that satisfies a predetermined reference value, the support design unit 107 outputs a design domain parameter that satisfies the reference value and minimizes the amount of support 7a. For example, the support design unit 107 causes the molding deformation amount analysis unit 103 to calculate multiple molding deformation amounts when supports 7a are added to the design model 5 within the support design area 7 by continuously changing the design domain parameter that defines the specifications of the support 7a, and when a molding deformation amount that satisfies the reference value set by the reference value setting unit 105 is calculated, the support design unit 107 outputs a design domain parameter that satisfies the reference value and minimizes the amount of support 7a. FIG. 12 shows an example of calculation of an estimated value of a molding deformation amount when the design domain parameter is changed from 0 to 100% as a support equivalent stiffness. In the example shown in FIG. 12, if the support equivalent stiffness is set to 50% or more, the molding deformation amount becomes equal to or less than the reference value of 0.4 mm. In this case, a support equivalent stiffness of 50% corresponds to the design domain parameters that satisfy the reference value and have the minimum amount of supports 7a, and therefore the support design unit 107 outputs a support equivalent stiffness of 50%. Note that the minimum amount of supports 7a means, for example, a case where the mass or volume of the supports 7a to be molded is minimum (i.e., a case where the mass of the powder material is minimum).

[0030] The support shape setting unit 108 sets the three-dimensional shape of the support 7a to be modeled based on the support design area 7 set by the support design area setting unit 106 and the design area parameters output by the support design unit 107. The support shape setting unit 108 selects, for example, one of a plurality of shape patterns prepared in advance according to an instruction operation by a user, and sets the shape of the support 7a by changing the shape and density based on the design area parameters. Fig. 13 shows an example of the support 7a set by the support shape setting unit 108 when a support equivalent stiffness of 50% is applied to the support design area 7 shown in Fig. 11.

[0031] The molding deformation amount analysis adjustment unit 109 first creates a model (a model without inverse distortion correction) in which the supports 7a set by the support shape setting unit 108 are added to the design model 5, and outputs the model from the CAD data output unit 111, thereby molding the object 50 (hereinafter also referred to as a supported object) in a state in which the scaffolding supports 54 and the supports 7a are added by the molding device 2. Alternatively, when the reference value setting unit 105 determines not to install the supports 7a, the molding deformation amount analysis adjustment unit 109 first outputs the design model 5 (a model without inverse distortion correction) from the CAD data output unit 111, thereby molding the object 50 in a state in which only the scaffolding supports 54 are added by the molding device 2. Next, the molding deformation amount analysis adjustment unit 109 acquires the result of measuring the molding deformation amount of the object by the measuring device 3 via the shape measurement data acquisition unit 102. Next, the molding deformation amount analysis adjustment unit 109 adjusts the analysis parameters so that the molding deformation amount estimated by the molding deformation amount analysis unit 103 matches the molding deformation amount measured of the model.

[0032] The inverse distortion correction setting unit 110 estimates the molding deformation amount using the molding deformation amount analysis unit 103 using the analysis parameters adjusted by the molding deformation amount analysis adjustment unit 109, creates a design model (model with inverse distortion correction) by applying inverse distortion correction to a model (model without inverse distortion correction) in which support 7a is added to design model 5, and outputs it from the CAD data output unit 111, whereby, for example, scaffolding support 54 and support 7a are added in the molding device 2, and a molded object 50 is molded in a state in which it has been further inversely corrected.

[0033] The CAD data output unit 111 outputs the design model (model without inverse distortion correction) created by the modeling deformation amount analysis adjustment unit 109, the design model (model with inverse distortion correction) created by the inverse distortion correction setting unit 110, etc., in accordance with, for example, STL (a file format for allowing the geometric shape of a 3D model to be read into an AM device for producing a modeled object), and the modeled object is manufactured by the modeling device 2.

[0034] Next, an example of the operation of the support design device 4 will be described with reference to Figures 14 and 15. The flow charts shown in Figures 14 and 15 are connected to each other by a connector C1.

[0035] 14 and 15 are started in response to, for example, a predetermined instruction operation by a user. In the process shown in Fig. 14 etc., first, the design model acquisition unit 101 acquires the design model 5 (step S11).

[0036] Next, the molding deformation amount analysis unit 103 executes molding deformation analysis without the supports 7a and calculates the molding deformation amount (step S12). Next, the reference value setting unit 105 refers to the correlation information database 104 and determines a reference value of the molding deformation amount (step S13). Next, the reference value setting unit 105 compares the set reference value with the molding deformation amount calculated by the molding deformation amount analysis unit 103 in step S12, and determines whether the molding deformation amount is equal to or less than the reference value (step S14). If the molding deformation amount is equal to or less than the reference value (step S14: YES), the reference value setting unit 105 decides not to install supports (step S15).

[0037] If the molding deformation amount is not equal to or less than the reference value (step S14: NO), the support design area setting unit 106 sets the support design area 7 of the support 7a (step S16). Next, the molding deformation amount analysis unit 103 executes a molding deformation analysis in which the design area parameters are continuously changed (step S17). Next, the support design unit 107 determines whether or not there are design area parameters that make the molding deformation amount equal to or less than the reference value (step S18).

[0038] If there are no design area parameters for which the molding deformation amount is below the reference value (step S18: NO), the support design area setting unit 106 sets a support design area 7 with different supports 7a (step S16), and the molding deformation amount analysis unit 103 re-performs the molding deformation analysis by continuously changing the design area parameters (step S17).

[0039] If there are design domain parameters for which the molding deformation amount is equal to or less than the reference value (step S18: YES), the support design unit 107 outputs the design domain parameters for which the molding deformation support amount is minimum and the molding deformation amount is equal to or less than the reference value (step S19). Next, the support shape setting unit 108 creates a design model in which supports 7a based on the design domain parameters output by the support design unit 107 are added to the design model 5 (step S20).

[0040] After step S20 or step S15, the modeling deformation amount analysis adjustment unit 109 first outputs a model in which the supports 7a set by the support shape setting unit 108 are added to the design model 5, or a model in which the supports 7a are not added to the design model 5, from the CAD data output unit 111, thereby forming a modeled object 50 without reverse distortion correction with the scaffolding supports 54 and supports 7a added by the modeling device 2, or a modeled object 50 without reverse distortion correction with the scaffolding supports 54 added by the modeling device 2 (step S21).

[0041] Next, the shape measurement data acquisition unit 102 acquires the results of the measurement by the measuring device 3 of the amount of molding deformation of the molded object 50 without inverse distortion correction when the support 7a and the scaffolding support 54 are added or when only the scaffolding support 54 is added (step S22).

[0042] Next, the molding deformation amount analysis adjustment unit 109 adjusts the analysis parameters of the molding deformation analysis to match the shape measurement results (step S23). Next, the inverse distortion correction setting unit 110 creates a design model that has been inversely corrected using the molding deformation analysis (step S24). Next, the CAD data output unit 111 outputs the CAD data, and the molding device 2 molds the molded object 50 with the inverse distortion correction (step S25).

[0043] (Action and effect) In the support design device, support design method, and program configured as described above, when designing supports 7a that are formed integrally with the object 50 to suppress deformation of the object 50 formed by additive manufacturing, first, the necessity of the supports 7a is determined based on the estimation result of the amount of deformation of the object 50. If the supports 7a are necessary, first, a support design area 7, which is an area where the supports 7a are added to the design model 5, is set, and then, multiple amounts of deformation of the support 7a when the support 7a is added within the support design area 7 are calculated by continuously changing the design area parameters that define the specifications of the support 7a. When a molding deformation amount that satisfies a predetermined reference value is calculated, the design area parameters that satisfy the reference value and minimize the amount of the support 7a are output. According to this configuration, for example, when there are multiple specifications that satisfy the reference value, the specification that minimizes the amount of the support is selected. Therefore, it is possible to appropriately design supports to suppress deformation of the object.

[0044] (Modification) Although an embodiment of the present invention has been described above with reference to the drawings, the specific configuration is not limited to the above embodiment, and also includes design modifications and the like within the scope of the gist of the present invention.

[0045] For example, in order to perform support minimization more precisely, the following processing may be performed before performing an analysis (hereinafter referred to as analysis (2)) in which the modeling deformation amount of a model to which supports 7a are added within the support design area 7 (this is referred to as a provisional support model) is calculated by continuously changing the design area parameters. That is, the support to be added within the support design area 7 may be thinned by utilizing a structural weight reduction analysis. Specifically, the displacement of the product part (model 50) obtained in the analysis of the modeling deformation amount for the design model before the supports 7a are added (hereinafter referred to as analysis (1)) is given to the provisional support model as a forced displacement, and the user sets a provisional volume reduction amount (for example, 30%), and then outputs a structure with maximum rigidity. If the structure obtained here has a part with an overhang of 45 degrees or more, the shape is corrected to be 45 degrees or more, taking into account the modeling property. This model may be used as the provisional support model in analysis (2). In this configuration, the shape of the support 7a based on the modeling deformation amount calculated without supports (the deformation amount calculated in analysis (1)) is set in the support design area 7. Therefore, according to this configuration, the support 7a can be designed with high accuracy, compared to a case where the shape is not set based on the analysis (1).

[0046] Computer Configuration FIG. 16 is a schematic block diagram illustrating a configuration of a computer according to at least one embodiment. The computer 90 comprises a processor 91, a main memory 92, a storage 93, and an interface 94. The support design device 4 described above is implemented in a computer 90. The operations of the above-mentioned processing units are stored in the form of a program in a storage 93. A processor 91 reads the program from the storage 93, loads it in a main memory 92, and executes the above-mentioned processing in accordance with the program. The processor 91 also secures storage areas in the main memory 92 corresponding to the above-mentioned storage units in accordance with the program.

[0047] The program may be for realizing a part of the functions to be performed by the computer 90. For example, the program may be for realizing the functions by combining with other programs already stored in the storage or by combining with other programs implemented in other devices. In another embodiment, the computer may include a custom LSI (Large Scale Integrated Circuit) such as a PLD (Programmable Logic Device) in addition to or instead of the above configuration. Examples of PLDs include PAL (Programmable Array Logic), GAL (Generic Array Logic), CPLD (Complex Programmable Logic Device), and FPGA (Field Programmable Gate Array). In this case, some or all of the functions to be realized by the processor may be realized by the integrated circuit.

[0048] Examples of the storage 93 include a hard disk drive (HDD), a solid state drive (SSD), a magnetic disk, a magneto-optical disk, a compact disc read only memory (CD-ROM), a digital versatile disc read only memory (DVD-ROM), and a semiconductor memory. The storage 93 may be an internal medium directly connected to the bus of the computer 90, or an external medium connected to the computer 90 via an interface 94 or a communication line. In addition, when the program is distributed to the computer 90 via a communication line, the computer 90 that receives the program may load the program into the main memory 92 and execute the above-mentioned process. In at least one embodiment, the storage 93 is a non-transitory tangible storage medium.

[0049] <Additional Notes> The support design device 4 described in this embodiment can be understood, for example, as follows.

[0050] (1) A support design device 4 according to a first aspect is a device for designing supports (supports 7a) that are formed integrally with a model 50 to suppress deformation of the model 50 formed by additive manufacturing, and includes a design model acquisition unit 101 that acquires a design model 5 representing the model 50, a support design area setting unit 106 that sets a support design area 7 that is an area where the supports 7a are added to the design model 5, a deformation amount analysis unit (modeling deformation amount analysis unit 103) that continuously changes parameters that define the specifications of the supports and calculates multiple deformation amounts that are the magnitude of deviation of the model 50 from the design model when the supports 7a are added within the support design area 7, and a support design unit 107 that outputs the parameters that satisfy the reference value and minimize the amount of the supports when the deformation amount analysis unit calculates the deformation amount that satisfies a predetermined reference value. According to this aspect and each of the following aspects, supports for suppressing deformation of the model can be appropriately designed.

[0051] (2) A support design device 4 according to a second aspect is the support design device 4 according to (1), in which the parameters include a value representing the equivalent stiffness of the support design region (support design region 7). According to this aspect, the support specifications can be easily set and changed by the value representing the equivalent stiffness.

[0052] (3) A support design device 4 according to a third aspect is the support design device 4 according to (1) or (2), in which the design model includes in advance a second support (scaffolding support 54) that suppresses deformation of the shaped object in the stacking direction. According to this aspect, it is possible to appropriately design a design model including the second support.

[0053] (4) A support design device 4 according to a fourth aspect is the support design device 4 according to (3), in which the second support has a lower rigidity than the support in a direction perpendicular to the stacking direction. According to this aspect, it is possible to appropriately design a design model including a second support having a lower rigidity than the support in a direction perpendicular to the stacking direction.

[0054] (5) A support design device 4 according to a fifth aspect is the support design device 4 according to any one of (1) to (4), and the reference value is a value that is based on the premise of performing inverse distortion correction, which is a correction that deforms the design model in a direction opposite to the predicted deformation. According to this aspect, it is possible to easily design a support to be combined with inverse distortion correction.

[0055] (6) A support design device 4 according to a sixth aspect is the support design device 4 according to any one of (1) to (5), wherein the deformation amount analysis unit (modeling deformation amount analysis unit 103) estimates the deformation amount of the model 50 based on the design model 5 before the inverse distortion correction. According to this aspect, the calculation process of the deformation amount of the model can be simplified more easily than when a design model to which the inverse distortion correction has been applied is used.

[0056] (7) A support design device 4 according to a seventh aspect is the support design device 4 of (1) to (6), in which the reference value is set based on a correlation between the estimated deformation amount and an actual measurement value of shape accuracy based on the modeling result after the inverse distortion correction. According to this aspect, the reference value can be set based on the correlation between the estimated deformation amount and an actual measurement value of shape accuracy based on the modeling result after the inverse distortion correction.

[0057] (8) The support design device 4 according to an eighth aspect is the support design device 4 according to any one of (1) to (7), wherein the shape of the support is set in the support design area based on the deformation amount calculated without the support. According to this aspect, the support can be designed with high accuracy. [Explanation of symbols]

[0058] 1. Additive manufacturing system 2... Molding device 3. Measurement equipment 4…Support design device 5. Design model 50…Sculpted object 51...Cylindrical part 52…Tabletop 53...Cylindrical section 54…Scaffolding support 7…Support design area 7a…Support 101…Design model acquisition section 102...shape measurement data acquisition unit 103…Modeling deformation analysis section 104…Correlation information database 105...Reference value setting section 106…Support design area setting section 107…Support Design Department 108…Support shape setting section 109…Modeling deformation amount analysis adjustment section 110…Inverse distortion correction setting section 111…CAD data output section

Claims

1. An apparatus for designing a support that is integrally formed with a structure to suppress deformation of the structure formed by additive manufacturing, comprising: a design model acquisition unit that acquires a design model representing the object; a support design area setting unit that sets a support design area, which is an area where the support is added to the design model; a deformation amount analysis unit that calculates a plurality of deformation amounts, which are magnitudes of deviations of the object from the design model, when the support is added within the support design region by continuously changing parameters that define specifications of the support; a support design unit that outputs the parameters that satisfy the reference value and minimize the amount of support when the deformation amount analysis unit calculates the deformation amount that satisfies a predetermined reference value; A support design device comprising:

2. The parameters include a value representing an equivalent stiffness of the support design domain. The support design device according to claim 1 .

3. The design model includes in advance a second support that suppresses deformation of the object in a stacking direction. The support design device according to claim 1 .

4. The second support has a lower rigidity than the first support in a direction perpendicular to the stacking direction. The support design device according to claim 3 .

5. The reference value is a value that is based on the assumption that an inverse distortion correction, which is a correction that distorts the design model in a direction opposite to the predicted deformation, is performed. The support design device according to any one of claims 1 to 4.

6. The deformation amount analysis unit estimates a deformation amount of the object based on the design model before the inverse distortion correction. The support design device according to claim 5 .

7. The reference value is set based on a correlation between the estimated deformation amount and an actual measurement value of shape accuracy based on the molding result after the inverse distortion correction. The support design device according to claim 5 .

8. In the support design region, a shape of the support based on the deformation amount calculated without the support is set. The support design device according to claim 5 .

9. A method for designing a support that is integrally formed with a structure to suppress deformation of the structure formed by additive manufacturing, comprising the steps of: obtaining a design model representative of the object; A step of setting a support design area, which is an area where the support is added to the design model; a step of calculating a plurality of deformation amounts, which are the magnitudes of deviations of the object from the design model when the supports are added within the support design region by continuously changing parameters that define specifications of the supports; When the deformation amount that satisfies a predetermined reference value is calculated, outputting the parameters that satisfy the reference value and minimize the amount of support; Support design methods including:

10. Calculating the deformation without the support. The support design method according to claim 9.

11. A program for designing a support that is integrally formed with a modeled object in order to suppress deformation of the modeled object formed by additive manufacturing, comprising: obtaining a design model representative of the object; A step of setting a support design area, which is an area where the support is added to the design model; a step of calculating a plurality of deformation amounts, which are the magnitudes of deviations of the object from the design model when the supports are added within the support design region by continuously changing parameters that define specifications of the supports; When the deformation amount that satisfies a predetermined reference value is calculated, outputting the parameters that satisfy the reference value and minimize the amount of support; A program that causes a computer to execute the following.

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