Method and system for generating computer object data for additive manufacturing

Abstract

A method for generating computer object data for additive manufacturing includes the steps of: displaying a graphical user interface (GUI); loading image data describing a two-dimensional image selected by the GUI; and defining a plurality of separate tiling elements, each relating to a different part of the image data, based on a tiling pattern selected by the GUI. The method further includes the step of displaying a three-dimensional image on the GUI, each including a plurality of separate protruding elements, each extending outward from the tiling elements, wherein each protruding element has a three-dimensional shape selected by a relief selection control set, and at least a segment of each protruding element has at least one intensity level, corresponding to each part of the image data. The method further includes the step of generating computer object data describing the protruding elements.

Description

Technical Field

[0001] Related Applications This application claims the benefit of priority of U.S. Provisional Patent Application No. 63 / 471,538, filed on June 7, 2023, the entire content of which is incorporated herein by reference.

[0002] In some embodiments, the present invention relates to additive manufacturing, and more particularly, but not limited to, methods and systems for generating computer object data for additive manufacturing.

Background Art

[0003] Additive manufacturing (AM) is a technology that enables the direct shaping of a formed structure from computer data through additive forming steps. The basic operation of any AM system consists of slicing a three-dimensional computer model into thin cross-sections, converting the result into two-dimensional position data, and supplying that data to control equipment that forms the three-dimensional structure in layers.

[0004] Additive manufacturing requires many different techniques for forming methods including three-dimensional (3D) printing such as 3D inkjet printing. 3D inkjet printing is performed by inkjet deposition of layers of a build material. Thus, the build material is ejected from a dispensing head having a set of nozzles for depositing layers on a support structure. These layers are then leveled by a leveling device and cured or solidified.

[0005] Various three-dimensional printing techniques exist, as disclosed, for example, in U.S. Patents 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. Published Patent No. 20060054039, and International Publications WO2016 / 009426 and WO2022 / 024114, all by the same assignee, and thus the whole is incorporated by reference. For example, international application WO2022 / 024114 describes a system for three-dimensional printing comprising an array of nozzles for dispensing construction material, a work tray, a jig for attaching fabric to the work tray, and a computerized controller for operating the array of nozzles to dispensing construction material onto the attached fabric. An imaging system may be configured to image the fabric placed on the work tray, and the image data received from the imaging system may be processed to identify a pattern on the fabric, and the nozzles dispensing construction material to selected locations for the identified features. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] U.S. Patent No. 6,259,979 [Patent Document 2] U.S. Patent No. 6,569,373 [Patent Document 3] U.S. Patent No. 6,658,314 [Patent Document 4] U.S. Patent No. 6,850,334 [Patent Document 5] U.S. Patent No. 6,863,859 [Patent Document 6] U.S. Patent No. 7,183,335 [Patent Document 7] U.S. Patent No. 7,209,797 [Patent Document 8] U.S. Patent No. 7,225,045 [Patent Document 9] U.S. Patent No. 7,300,619 [Patent Document 10] U.S. Patent No. 7,500,846 [Patent Document 11] U.S. Patent No. 9,031,680 [Patent Document 12] U.S. Patent No. 9,227,365 [Patent Document 13] U.S. Published Patent No. 20060054039 [Patent Document 14] International release WO2016 / 009426 [Patent Document 15] International release WO2022 / 024114 [Overview of the Initiative] [Means for solving the problem]

[0007] According to one aspect of several embodiments of the present invention, a method for generating computer object data for additive manufacturing is provided. The method includes the steps of: displaying a graphical user interface (GUI) having an image selection control set, a tiling selection control set, and a relief selection control set; loading image data describing a two-dimensional image selected by the image selection control set; and defining a plurality of separate tiling elements, each relating to a different part of the image data, based on a tiling pattern selected by the tiling selection control set. The method further includes the step of displaying a three-dimensional image on the GUI, each including a plurality of separate protruding elements jutting out of the tiling elements of the tiling pattern, wherein each protruding element has a three-dimensional shape selected by the relief selection control set, and at least a segment of each protruding element has at least one intensity level, depending on the respective part of the image data. The method further includes the steps of generating computer object data describing the protruding elements and storing the computer object data in computer storage.

[0008] According to some embodiments of the present invention, this method includes the step of identifying background areas and non-background areas in an image, where individual tiling elements tile only the non-background areas.

[0009] According to some embodiments of the present invention, the tiling selection control set is configured to allow the user to independently select the shape of the tiling elements and the spacing between the tiling elements.

[0010] According to some embodiments of the present invention, the tiling selection control set is configured to allow the user to independently select the size of the tiling elements.

[0011] According to some embodiments of the present invention, the tiling selection control set is configured to enable a user to select different sizes for different tiling elements.

[0012] According to some embodiments of the present invention, the tiling selection control set is configured to enable a user to select different intervals between different pairs of tiling elements.

[0013] According to some embodiments of the present invention, the relief selection control set is configured to enable a user to select at least one of (i) different heights for different protrusion elements, (ii) different intervals between different pairs of protrusion elements, and (iii) different cross-sectional sizes for different protrusion elements.

[0014] According to some embodiments of the present invention, the relief selection control set is configured to automatically select at least one of (i) different heights for different protrusion elements, (ii) different intervals between different pairs of protrusion elements, and (iii) different cross-sectional sizes for different protrusion elements.

[0015] According to some embodiments of the present invention, the relief selection control set is configured to select the height of the protrusion elements based on each part of the image data.

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

[0017] According to some embodiments of the present invention, the GUI includes a height map control set configured to generate or import a height map, and the relief selection control set is configured to select the height of the protrusion elements based on the height map.

[0018] According to some embodiments of the present invention, the GUI includes a density map control set configured to generate or import a density map, and the relief selection control set is configured to select the density of the protrusion elements based on the density map.

[0019] According to some embodiments of the present invention, the GUI includes a size map control set configured to generate or import a size map, and the relief selection control set is configured to select the cross-sectional size of the protrusion elements based on the size map.

[0020] According to some embodiments of the present invention, the GUI includes a lenticularization control set configured to enable the user to select a lenticularization method, and the shape, color, and transparency level of the protrusion elements are selected based on the lenticularization method.

[0021] According to some embodiments of the present invention, the GUI includes a lenticularization control set configured to enable the GUI to instruct the user to automatically select a lenticularization method, and the shape, color, and transparency level of the protrusion elements are selected based on the lenticularization method.

[0022] According to some embodiments of the present invention, the method includes the steps of slicing computer object data into a plurality of slices, each defined for a plurality of voxels, and storing the slices in computer storage. According to one aspect of some embodiments of the present invention, a method for additive manufacturing is provided. This method includes the steps of carrying out the method as described above, and optionally, preferably, as further detailed below, namely loading the slices generated by this method from computer storage; assigning a construction material to each voxel in each slice according to at least one strength level of each protruding element containing the voxel; and transmitting the plurality of slices and their respective construction material assignments to a controller of an additive manufacturing system for additive manufacturing of a plurality of layers, each corresponding to a plurality of slices.

[0023] According to one aspect of several embodiments of the present invention, a computer software product is provided. The computer software product comprises a computer-readable medium in which program instructions are stored, and when the program instructions are read by a data processor, the data processor causes the data processor to perform a method as described above, and optionally, preferably, as further detailed below.

[0024] According to one aspect of several embodiments of the present invention, a method for additive manufacturing is provided. This method includes the steps of carrying out the method as described above, and optionally, preferably, as further detailed below, namely, loading computer object data from computer storage; slicing the computer object data into a plurality of slices, each defined for a plurality of voxels; assigning a construction material to each voxel in each slice according to at least one strength level of each protruding element containing the voxel; and transmitting the plurality of slices and their respective construction material assignments to a controller of an additive manufacturing system for additive manufacturing of a plurality of layers, each corresponding to a plurality of slices.

[0025] According to some embodiments of the present invention, this method includes the step of placing a fabric on a tray of an additive manufacturing system so that multiple layers are formed on the fabric by the system.

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

[0027] Unless otherwise defined, all technical and / or scientific terms used herein have the same meaning as commonly understood by those skilled in the art to whom the present invention relates. Similar or equivalent methods and materials to those described herein may be used in the practice or testing of embodiments of the present invention, but exemplary methods and / or materials are described below. In case of any conflict, the patent specification shall prevail, including the definitions. In addition, these materials, methods, and examples are illustrative and not necessarily intended to be limiting.

[0028] Implementations of the methods and / or systems of embodiments of the present invention may require performing or completing selected tasks manually, automatically, or in combination thereof. Furthermore, according to the actual means and equipment of embodiments of the methods and / or systems of the present invention, some selected tasks may be implemented by hardware, software, firmware, or an operating system, or in combination thereof.

[0029] For example, hardware for performing a selected task according to embodiments of the present invention may be implemented as a chip or circuit. In the case of software, a selected task according to embodiments of the present invention may be implemented as a set of software instructions executed by a computer using any preferred 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 a set of instructions. Optionally, the data processor includes volatile memory for storing instructions and / or data, and / or non-volatile storage for storing instructions and / or data, such as a magnetic hard disk and / or removable media. Optionally, network connectivity is also provided. A display and / or user input devices such as a keyboard or mouse are also optionally provided.

[0030] Some embodiments of the present invention are described herein merely as examples, with reference to the accompanying drawings. With further detailed reference to the drawings, it is emphasized that the details shown are illustrative and intended to illustrate the discussion of embodiments of the present invention. In this regard, the description provided in conjunction with the drawings will make it clear to those skilled in the art how embodiments of the present invention may be put into practice. [Brief explanation of the drawing]

[0031] [Figure 1A] This is a schematic diagram of an additive manufacturing system according to an embodiment of the present invention. [Figure 1B] This is a schematic diagram of an additive manufacturing system according to an embodiment of the present invention. [Figure 1C] This is a schematic diagram of an additive manufacturing system according to an embodiment of the present invention. [Figure 1D] This is a schematic diagram of an additive manufacturing system according to an embodiment of the present invention. [Figure 2A] This is a schematic diagram of a print head according to an embodiment of the present invention. [Figure 2B]This is a schematic diagram of a print head according to an embodiment of the present invention. [Figure 2C] This is a schematic diagram of a print head according to an embodiment of the present invention. [Figure 3A] This is a schematic diagram illustrating a coordinate transformation according to an embodiment of the present invention. [Figure 3B] This is a schematic diagram illustrating a coordinate transformation according to an embodiment of the present invention. [Figure 4A] This is a schematic diagram of a graphical user interface (GUI) suitable for implementing a method for converting a two-dimensional image into computer object data according to an embodiment of the present invention. [Figure 4B] This is a schematic diagram of a graphical user interface (GUI) suitable for implementing a method for converting a two-dimensional image into computer object data according to an embodiment of the present invention. [Figure 4C] This is a schematic diagram of a graphical user interface (GUI) suitable for implementing a method for converting a two-dimensional image into computer object data according to an embodiment of the present invention. [Figure 4D] This is a schematic diagram of a graphical user interface (GUI) suitable for implementing a method for converting a two-dimensional image into computer object data according to an embodiment of the present invention. [Figure 4E] This is a schematic diagram of a graphical user interface (GUI) suitable for implementing a method for converting a two-dimensional image into computer object data according to an embodiment of the present invention. [Figure 4F] This is a schematic diagram of a graphical user interface (GUI) suitable for implementing a method for converting a two-dimensional image into computer object data according to an embodiment of the present invention. [Figure 5A] This is a schematic diagram of a projection element that can be used by a method according to an embodiment of the present invention. [Figure 5B] This is a schematic diagram of a projection element that can be used by a method according to an embodiment of the present invention. [Figure 5C]This is a schematic diagram of a projection element that can be used by a method according to an embodiment of the present invention. [Figure 5D] This is a schematic diagram of a projection element that can be used by a method according to an embodiment of the present invention. [Figure 5E] This is a schematic diagram of a projection element that can be used by a method according to an embodiment of the present invention. [Figure 5F] This is a schematic diagram of a projection element that can be used by a method according to an embodiment of the present invention. [Figure 6] This flowchart illustrates a method suitable for generating computer object data for additive manufacturing, according to several embodiments of the present invention. [Figure 7A] This is a schematic diagram of protruding elements characterized by different finesse values. [Figure 7B] This is a schematic diagram of protruding elements characterized by different finesse values. [Figure 8A] This is a schematic diagram of protruding elements characterized by different severity values. [Figure 8B] This is a schematic diagram of protruding elements characterized by different severity values. [Modes for carrying out the invention]

[0032] In some embodiments, the present invention relates to additive manufacturing, and more specifically, to a method and system for generating computer object data for additive manufacturing, without limitation.

[0033] Before describing in detail at least one embodiment of the present invention, it should be understood that the present invention is not necessarily limited in its application to the details of the construction and arrangement of components and / or methods described below and / or shown in the drawings and / or examples. Other embodiments of the present invention are possible or can be practiced or carried out in various ways.

[0034] The method and system of this embodiment manufacture a three-dimensional object in layers based on computer object data by forming multiple layers into a configured pattern corresponding to the shape of the object. The layer formation is optionally, preferably, by printing, more preferably by jet printing. The computer object data may be any known format, but is not limited to, Standard Tessellation Language (STL) or StereoLithography Contour (SLC) format, OBJ file format (OBJ), Manufacturing Format (3MF), Virtual Reality Modeling Language (VRML), Additive Manufacturing File (AMF) format, Drawing Exchange Format (DXF), Polygon File Format (PLY), or any other format suitable for Computer-Aided Design (CAD).

[0035] Computer object data can be a data structure containing multiple graphical elements (e.g., a polygon mesh, a non-uniform rational B-spline, etc.). Generally, the graphical elements are converted into a grid of voxels that define the shape of the object, for example, by using a slicing procedure that forms multiple slices, each containing multiple voxels that describe layers of the 3D object.

[0036] Since a grid of voxels and multiple graphic elements describe the same object, the term “computer object data” is used herein in reference to both a grid of voxels and multiple graphical elements. Thus, when computer object data relates to a grid of voxels, each element of the computer object data is a voxel, and when computer object data relates to a graphic element, each element of the computer object data is a graphic element, such as a polygon or a spline.

[0037] As used herein, the term "object" refers to an entire three-dimensional object or a part thereof.

[0038] Each layer can be formed by an AM (additive manufacturing) apparatus that scans a two-dimensional surface and shapes it (patterns). During scanning, the apparatus visits multiple target locations on the two-dimensional layer or surface and determines, for each target location or group of target locations, whether the target location or group of target locations is occupied by a formulation, and what type of formulation is dispensed there. This determination is made according to a computer image of the surface.

[0039] In preferred embodiments of the present invention, AM includes three-dimensional printing, more preferably three-dimensional inkjet printing. In these embodiments, the build material is ejected from a printhead having one or more arrays of nozzles for layering the build material onto a support structure. The AM apparatus thus ejects the build material into target locations that will be occupied, leaving other target locations empty. The apparatus generally includes multiple arrays of nozzles, each of which may be configured to eject a different build material. This is generally achieved by providing a printhead with multiple fluid channels separated from each other, each channel receiving a different build material through a separate inlet and transporting it to a different array of nozzles.

[0040] Therefore, different target locations may be occupied by different construction material formulations. The types of construction material formulations can be classified into two main categories: modeling material formulations and support material formulations. Support material formulations function as support matrices or support structures for supporting an object or part of an object during the molding process and / or other purposes, for example, during the provision of a hollow or porous object. Support structures may also include modeling material formulation elements, for example, for additional support strength.

[0041] Modeling material formulations are generally compositions formulated for use in additive manufacturing, capable of forming three-dimensional objects on their own, i.e., without the need to mix or combine them with any other materials.

[0042] The final three-dimensional object is created by a modeling material formulation, a combination of modeling material formulations, a combination of modeling material formulations and support material formulations, or by modifications thereof (for example, following curing). All these operations are well known to those skilled in the art of solid freedom fabrication.

[0043] In some exemplary embodiments of the present invention, an object is manufactured by extruding two or more different modeling material formulations, each being a material formulation from a different array of nozzles (belonging to the same or different printheads) of an AM apparatus. In some embodiments, both of the two or more arrays of such nozzles extruding different modeling material formulations are located on the same printhead of the AM apparatus. In some embodiments, the arrays of nozzles extruding different modeling material formulations are located in separate printheads, for example, a first array of nozzles extruding a first modeling material formulation is located in a first printhead, and a second array of nozzles extruding a second modeling material formulation is located in a second printhead.

[0044] In some embodiments, both the array of nozzles for ejecting the modeling material formulation and the array of nozzles for ejecting the support material formulation are located within the same print head. In some embodiments, the array of nozzles for ejecting the modeling material formulation and the array of nozzles for ejecting the support material formulation are located within separate print heads.

[0045] A representative and non-limiting example of a system 110 suitable for AM of object 112, according to some embodiments of the present invention, is shown in Figure 1A. The system 110 comprises an additive manufacturing apparatus 114 having an ejection unit 16 with a plurality of print heads. Each head preferably comprises one or more arrays 22 of nozzles mounted on an orifice plate 121, as shown in Figures 2A to 2C described below, through which a fluid build material formulation 124 is ejected.

[0046] Preferably, though not required, apparatus 114 is a three-dimensional printing apparatus, in which case the print head is an inkjet print head, and the build material formulation is ejected via inkjet technology. Although not necessarily required, in some applications the additive manufacturing apparatus does not necessarily have to employ three-dimensional printing techniques. Typical examples of additive manufacturing apparatuses intended according to various exemplary embodiments of the present invention include, but are not limited to, fused deposition modeling apparatuses and fused material formulation deposition apparatuses.

[0047] Each printhead is fed through one or more build material mixture reservoirs, which may optionally, preferably optionally, include a temperature control unit (e.g., a temperature sensor and / or heating device) and a build material mixture level sensor. To eject the build material mixture, a voltage signal is applied to the printhead to selectively deposit droplets of the build material mixture through the printhead nozzles, for example, in piezo inkjet printing technology. Another example includes a thermal inkjet printhead. In these types of heads, there is a heating element that heats the build material mixture and makes thermal contact with the build material mixture to form bubbles within it when the heating element is activated by the voltage signal. The bubbles create pressure within the build material mixture, causing droplets of the build material mixture to be ejected through the nozzles. Piezo and thermal printheads are well known to those skilled in the art of solid free-form molding. For any type of inkjet printhead, the ejection rate of the head depends on the number of nozzles, the type of nozzles, and the voltage signal ratio (frequency) applied.

[0048] Optionally, the total number of ejection nozzles or nozzle arrays is selected such that half of the ejection nozzles are designed to eject a support material formulation and the other half are designed to eject a modeling material formulation; that is, the number of nozzles ejecting the modeling material formulation is the same as the number of nozzles ejecting the support material formulation. In a typical example in Figure 1A, four print heads 16a, 16b, 16c, and 16d are shown. Each of the heads 16a, 16b, 16c, and 16d has a nozzle array. In this example, heads 16a and 16b may be designed for modeling material formulations, and heads 16c and 16d may be designed for support material formulations. Thus, head 16a can eject one modeling material formulation, head 16b can eject another modeling material formulation, and both heads 16c and 16d can eject support material formulations. In an alternative embodiment, heads 16c and 16d may be combined, for example, to form a single head having two nozzle arrays for depositing support material formulations. In a further alternative embodiment, one or more of the print heads may have two or more nozzle arrays for depositing two or more material formulations, for example, two different modeling material formulations or two nozzle arrays for depositing a modeling material formulation and a support material formulation, with each formulation passing through a different array or a different number of nozzles.

[0049] However, it should be understood that this is not intended to limit the scope of the present invention, and the number of modeling material formulation printheads (modeling heads) and the number of support material formulation printheads (support heads) may vary. In some embodiments, the number of arrays of nozzles that eject the modeling material formulation, the number of arrays of nozzles that eject the support material formulation, and the number of nozzles in each respective array are selected to provide a predetermined ratio a between the maximum ejection rate of the support material formulation and the maximum ejection rate of the modeling material formulation. The value of the predetermined ratio a is preferably selected to ensure that, within each formed layer, the height of the modeling material formulation is equal to the height of the support material formulation. A common value for a is approximately 0.6 to approximately 1.5.

[0050] The term "approximately" as used throughout this specification refers to + / - 10%.

[0051] For example, when a=1, the total discharge rate of the support material formulation is generally the same as the total discharge rate of the modeling material formulation when all arrays of nozzles are operating.

[0052] The apparatus 114 may comprise, for example, M modeling heads, each having m arrays of p nozzles, and S support heads, each having s arrays of q nozzles, such that M × m × p = S × s × q. Each of the M × m modeling arrays and S × s support arrays may be manufactured as separate physical units that can be assembled and disassembled from a group of arrays. In this embodiment, each such array optionally, preferably, comprises its own temperature control unit and material formulation level sensor, and receives individually controlled voltages for its operation.

[0053] The apparatus 114 may further comprise a solidification device 18 which may include any device configured to emit light, heat, or the like that can solidify the deposited material formulation. For example, depending on the modeling material formulation used, the solidification device 18 may comprise one or more radiation sources, or other electromagnetic radiation sources, or electron beam sources, which may be, for example, ultraviolet lamps, visible light lamps, or infrared lamps. In some embodiments of the present invention, the solidification device 18 functions to cure or solidify the modeling material formulation.

[0054] In addition to the solidification device 18, the apparatus 114 optionally, preferably, includes an additional radiation source 328 for solvent evaporation. The radiation source 328 optionally, preferably, generates infrared radiation. In various exemplary embodiments of the present invention, the solidification device 18 includes a radiation source that generates ultraviolet radiation, and the radiation source 328 generates infrared radiation.

[0055] In some embodiments of the present invention, the apparatus 114 includes a cooling system 134, such as one or more fans.

[0056] The print head and radiation source are preferably mounted within a frame or block 128 that is preferably operable to move in opposition to each other on a tray 12 which serves as a work surface. In some embodiments of the present invention, the radiation source is mounted within a block so that it follows the print head and at least partially cures or solidifies the material formulation just ejected by the print head. The tray 12 is positioned horizontally. Following common practice, an XYZ Cartesian coordinate system is selected such that the XY planes are parallel to the tray 12. The tray 12 is preferably configured to move vertically (along the Z direction), generally downward. In various exemplary embodiments of the present invention, the apparatus 114 further comprises one or more leveling devices 32, for example, rollers 326. The leveling device 32 functions to stretch, level, and / or establish the thickness of a newly formed layer prior to forming a continuous layer thereon. The leveling device 32 preferably comprises a waste collection device 136 for collecting excess material formulation generated during leveling. The waste collection device 136 may include any mechanism for distributing the material mixture to a waste tank or waste cartridge.

[0057] During use, the printheads of unit 16 move in a scanning direction referred to herein as the X direction, selectively ejecting a construction material formulation in a predetermined configuration as they pass over the tray 12. The construction material formulation generally includes one or more types of support material formulations and one or more types of modeling material formulations. The modeling material formulation is cured by the radiation source 328 after the pass of the printheads of unit 16. Additional ejection of the construction material formulation may occur in a predetermined configuration during the reverse pass of the heads, returning to their starting points relative to the layers that have just been ejected. During the forward and / or reverse pass of the printheads, the layers formed thereby may preferably be stretched by a leveling device 32 that follows the path of the printheads during their forward and / or reverse movements. As the printheads return to their starting points along the X direction, the printheads may move to another position along the indexing direction referred to herein as the Y direction, and continue to build the same layers by reciprocal movement along the X direction. Alternatively, the printhead may move in the Y direction between forward and reverse movements, or after two or more 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.

[0058] Once a layer is complete, the tray 12 is lowered in the Z direction to a predetermined Z level according to the desired thickness of the layer to be printed next. This procedure is repeated to form a three-dimensional object 112 in layers.

[0059] In another embodiment, tray 12 may be transitioned in the Z direction within the layer between the forward and reverse paths of the print head of unit 16. Such a Z transition is performed to bring the leveling device into contact with the surface in one direction and prevent contact in the other direction.

[0060] This embodiment envisions the use of a fluid material compounding supply system 42 comprising one or more fluid material containers or cartridges 44 for supplying fluid material to a print head. The supply system 42 may be used within an AM system such as system 110, in which case the fluid material in each container is a construction material.

[0061] The controller 20 controls the molding apparatus 114 and optionally, preferably, also controls the supply system 42. The controller 20 generally includes electronic circuitry configured to perform control operations. The controller 20 preferably generally includes a display 25 and communicates with a computer 24 that transmits digital data relating to molding commands based on CAD configurations represented on a computer-readable medium in the form of computer object data, such as Standard Tessellation Language (STL) format. Generally, the controller 20 controls the voltage applied to each print head or each nozzle array and the temperature of the build material formulation within each print head or each nozzle array.

[0062] Once manufacturing data is loaded into the controller 20, the controller 20 can operate without user intervention. In some embodiments, the controller 20 receives additional input from an operator, for example, using a computer 24 or a user interface 116 communicating with the controller 20. The user interface 116 may be any type known in the art, but is not limited to a keyboard or touchscreen. For example, the controller 20 may receive as additional input one or more construction material formulation types and / or properties, but is not limited to color, characteristic strain, and / or transition temperature, rate, electrical properties, magnetic properties, etc. Other properties and groups of properties are also contemplated.

[0063] Another representative and non-limiting example of a system 10 suitable for object AM according to some embodiments of the present invention is shown in Figures 1B to 1D. Figures 1B to 1D show a plan view (Figure 1B), a side view (Figure 1C), and an isometric projection (Figure 1D) of system 10.

[0064] In this embodiment, the system 10 comprises a tray 12 and a plurality of inkjet printheads 16 having one or more arrays of nozzles, each having one or more distinct nozzles. The material used for three-dimensional printing is supplied to the heads 16 by a construction material supply system 42 using one or more fluid material containers or cartridges (not shown), as further detailed above. The tray 12 may have a disc shape, or the tray 12 may be annular. Non-circular shapes are also intended, provided that they can rotate about a vertical axis.

[0065] The tray 12 and head 16 are optionally, preferably mounted to allow relative rotational motion between the tray 12 and the head 16. This can be achieved by (i) configuring the tray 12 to rotate about a vertical axis 14 relative to the head 16, (ii) configuring the head 16 to rotate about a vertical axis 14 relative to the tray 12, or (iii) configuring both the tray 12 and the head 16 to rotate about the vertical axis 14 at different rotational speeds (e.g., in opposite directions). Some embodiments of System 10 are described below with particular emphasis on configuration (i) a rotating tray configured to rotate about a vertical axis 14 relative to the head 16, but it should be understood that this application also intends configurations (ii) and (iii) for System 10. Any of the embodiments of System 10 described herein are tunable to be applicable to either configuration (ii) and (iii), and those skilled in the art will know how to make such tunics once the details described herein are provided.

[0066] In the following description, the direction parallel to tray 12 and pointing outward from axis 14 is referred to as the radial direction r, and the direction parallel to tray 12 and perpendicular to radial direction r is referred to herein as the azimuthal direction.

number

[0067] The radial direction r in system 10 determines the index direction y in system 110, and the azimuth direction

number

[0068] 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 this term is used in reference to a printhead, it refers to the position of the head at a specific distance from the axis 14. When this term is used in reference to a point on the tray 12, it corresponds to any point that belongs to the locus of a circle whose radius is a specific distance from the axis 14 and whose center is the axis 14.

[0069] As used herein, the term "azimuthal position" refers to a position on or above the tray 12 at a specific azimuthal angle with respect to a given reference point. Therefore, the radial position refers to any point that belongs to the locus of points, which is a straight line forming a specific azimuthal angle with respect to the reference point.

[0070] As used herein, "vertical position" refers to a position on a plane that intersects the vertical axis 14 at a specific point.

[0071] The tray 12 functions as a construction platform for three-dimensional printing. The work area on which one or more objects are printed is generally, but not necessarily, smaller than the total area of ​​the tray 12. In some embodiments of the present invention, the work area is annular. The work area is shown in 26. In some embodiments of the present invention, the tray 12 rotates continuously in the same direction throughout the formation of the object, and in some embodiments of the present invention, the tray reverses the direction of rotation at least once (e.g., oscillating) during the formation of the object. The tray 12 is optionally, preferably, removable. Removal of the tray 12 is for maintenance of the system 10, or, if desired, to replace the tray before printing a new object. In some embodiments of the present invention, the system 10 is provided with one or more different replacement trays (e.g., a kit of replacement trays) on which two or more trays are designed for different types of objects (e.g., different weights), different operating modes (e.g., different rotation speeds), etc. Replacement of the tray 12 may be manual or automatic, as desired. When automatic replacement is employed, the system 10 includes a tray replacement device 36 configured to remove the tray 12 from its position under the head 16 and replace it with a replacement tray (not shown). In the representative diagram of Figure 1B, the tray replacement device 36 is shown as a drive 38 with a movable arm 40 configured to pull the tray 12, but other types of tray replacement devices are also conceivable.

[0072] Exemplary embodiments of the print head 16 are shown in Figures 2A to 2C. These embodiments can be applied to any of the AM systems described above, including, but are not limited to, system 110 and system 10.

[0073] Figures 2A and 2B show a printhead 16 with one (Figure 2A) and two (Figure 2B) nozzle arrays 22. The nozzles in the array are preferably linearly aligned along a straight line. The printhead 16 is fed by a fluid material and ejects it through the nozzle arrays 22 in response to a voltage applied to it by the controller of the printing system. The head 16 is fed by a fluid material which is a building material formulation.

[0074] In embodiments where a particular printhead has two or more linear nozzle arrays, the nozzle arrays may optionally, preferably, be parallel to each other. When a printhead has two or more arrays of nozzles (for example, Figure 2B), the same build material formulation may be fed to all arrays of the head, or different build material formulations may be fed to at least two arrays of the same head.

[0075] When a system similar to system 110 is employed, all print heads 16 are optionally, preferably, oriented along the index direction, having their positions along the scanning direction offset from one another.

[0076] When a system similar to system 10 is employed, all print heads 16 are optionally, preferably, oriented radially (parallel to the radial direction) at their azimuth positions offset from one another. Thus, in these embodiments, the nozzle arrays of different print heads are not parallel to one another, but rather at an angle to one another, and that angle is approximately equal to the azimuth offset between the respective heads. For example, one head is oriented radially, and at the azimuth position

number

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[0077] In some embodiments, two or more printheads may be assembled into a printhead block, in which case the printheads of the block are generally parallel to each other. A block containing several inkjet printheads 16a, 16b, 16c is shown in Figure 2C.

[0078] In some embodiments, the system 10 includes a stabilization structure 30 positioned below the head 16 such that the tray 12 is between the stabilization structure 30 and the head 16. The stabilization structure 30 may function to prevent or reduce vibrations of the tray 12 that may occur while the inkjet print head 16 is operating. In a configuration in which the print head 16 rotates around an axis 14, the stabilization structure 30 also preferably rotates so that the stabilization structure 30 is always directly below the head 16 (with the tray 12 between the head 16 and the tray 12).

[0079] The tray 12 and / or printhead 16 are optionally, preferably, configured to move along the vertical z parallel to the vertical axis 14 to change the vertical distance between the tray 12 and the printhead 16. In configurations where the vertical distance is different due to the tray 12 moving along the vertical direction, the stabilization structure 30 also preferably moves vertically with the tray 12. In configurations where the vertical distance is changed by the head 16 along the vertical direction while keeping the vertical position of the tray 12 fixed, the stabilization structure 30 also remains in a fixed vertical position.

[0080] Vertical motion can be established by the vertical drive 28. Once a layer is completed, the vertical distance between the tray 12 and the head 16 can be increased by predetermined vertical steps depending on the desired thickness of the subsequent layer to be printed (for example, the tray 12 is lowered relative to the head 16). This procedure is repeated to form a three-dimensional object in layers.

[0081] The operation of the inkjet print head 16, and optionally, preferably, one or more other components of the system 10, such as the movement of the tray 12, is controlled by the controller 20. The controller may have electronic circuits and a non-volatile memory medium readable by the circuits, which stores program instructions that, when read by the circuits, cause the circuits to perform control operations as further detailed below.

[0082] The controller 20 can also communicate with a host computer 24 that transmits digital data relating to molding commands based on computer object data, for example, in the form of Standard Tessellation Language (STL) or Stereolithography Contour (SLC) format, OBJ file format (OBJ), 3D Manufacturing Format (3MF), Virtual Reality Modeling Language (VRML), Additive Manufacturing File (AMF) format, Drawing Exchange Format (DXF), Polygon File Format (PLY), or any other format suitable for computer-aided design (CAD). The object data format is generally structured according to the Cartesian coordinate system. In these cases, the computer 24 preferably performs a procedure to convert the coordinates of each slice in the computer object data from the Cartesian coordinate system to the polar coordinate system. The computer 24 optionally, preferably, transmits the molding command from the perspective of the converted coordinate system. Alternatively, the computer 24 can transmit the molding command from the perspective of the original coordinate system provided by the computer object data, in which case the coordinate conversion is performed by the circuitry of the controller 20.

[0083] Coordinate transformation enables three-dimensional printing on a rotating tray. Non-rotating systems using a fixed tray with a printhead generally move in opposite directions along a straight line on the fixed tray. In such systems, the print resolution is the same at any point on the tray, provided that the head ejection rate is uniform. In system 10, unlike non-rotating systems, not all nozzles at the head point cover the same distance on the tray 12 simultaneously. Coordinate transformation is optionally, preferably, performed to ensure equal amounts of excess material formulation at different radial positions. Representative examples of coordinate transformation according to some embodiments of the present invention are shown in Figures 3A and 3B, which show three slices of an object (each slice corresponding to a molding instruction for a different layer of the object), where Figure 3A shows the slice in Cartesian coordinates and Figure 3B shows the same slice after the coordinate transformation procedure has been applied to each slice.

[0084] Generally, the controller 20 controls the voltage applied to each component of the system 10 based on molding instructions and, as described below, on stored program instructions.

[0085] Generally, the controller 20 controls the print head 16 to eject droplets of constituent material formulation in layers, such as to print a three-dimensional object on the tray 12, while the tray 12 is rotating.

[0086] System 10 optionally, preferably, depending on the modeling material formulation used, comprises one or more solidification devices 18, including, but not limited to, a radiation source, which may be, for example, an ultraviolet lamp, a visible light lamp, or an infrared lamp, or another source of electromagnetic radiation, or an electron beam source. The radiation source may include, but not limited to, any type of radiation emitting device, including light-emitting diodes (LEDs), digital light processing (DLP) systems, and resistive lamps. The solidification device 18 functions to cure or solidify the modeling material formulation. In various exemplary embodiments of the present invention, the operation of the solidification device 18 is controlled by a controller 20, which can activate or deactivate the solidification device 18 and optionally control the amount of radiation produced by the solidification device 18.

[0087] In some embodiments of the present invention, the system 10 further comprises one or more leveling devices 32, which may be manufactured as rollers or blades. The leveling devices 32 function to stretch a newly formed layer prior to forming a continuous layer thereon. In some embodiments, the leveling device 32 has the shape of a conical roller, with its axis of symmetry 34 inclined with respect to the surface of the tray 12 and its surface positioned parallel to the surface of the tray. This embodiment is shown in a side view of the system 10 (Figure 1C).

[0088] A conical roller may have the shape of a cone or a truncated cone.

[0089] The opening angle of the conical roller is preferably selected such that there exists a constant ratio between the radii of the cone at any location along its axis 34, and there is a distance between that location and the axis 14. This embodiment allows the roller 326 to efficiently level the layer because, while the roller rotates, any point p on the surface of the roller has a linear velocity proportional to (e.g., the same as) the linear velocity of the tray at a point vertically below point p. In some embodiments, the roller has the shape of a frustocone with height h, radius R1 at its closest distance from the axis 14, and radius R2 at its furthest distance from the axis 14, where the parameters h, R1, and R2 satisfy the relation R1 / R2=(Rh) / h, where R is the furthest distance of the roller from the axis 14 (e.g., R may be the radius of the tray 12).

[0090] The operation of the leveling device 32 is controlled by a controller 20, which can optionally, preferably, activate or deactivate the leveling device 32, and optionally control its position along the vertical (parallel to the axis 14) and / or along the radial (parallel to the tray 12 and toward or toward the axis 14).

[0091] In some embodiments of the present invention, the print head 16 is configured to move relative to the tray along a radial direction r. These embodiments are useful when the length of the nozzle array 22 of the head 16 is shorter than the radial width of the work area 26 on the tray 12. The radial movement of the head 16 is optionally, preferably, controlled by a controller 20.

[0092] Some embodiments intend to form an object by extruding different material formulations from different arrays of nozzles (belonging to the same or different printheads). These embodiments, in particular, provide the ability to select material formulations from a given number of material formulations and define a desired combination of the selected material formulations and their properties. According to these embodiments, the spatial location of the deposition of each material formulation having a layer is defined to enable spatial combinations of material formulations after deposition in each layer, thereby enabling either the occupation of different three-dimensional spatial locations by different material formulations to form a composite material formulation at each of one or more locations, or the occupation of three-dimensional locations adjacent to three-dimensional locations by substantially the same or two or more different material formulations.

[0093] Any post-deposition combination or mixing of modeling material formulations is intended. For example, when a material formulation is extruded, it may retain its original properties. However, when it is extruded simultaneously with another modeling material formulation, or with other extruded material formulations extruded at the same or nearby location, a composite material formulation having one or more properties different from the extruded material formulation may be formed.

[0094] In some embodiments of the present invention, the system extrudes two or more formulations into at least one of the layers to form a digital modeling material.

[0095] In this specification and as used in the art, the phrase “digital modeling material” describes a combination of two or more materials at the pixel level or voxel level such that pixels or voxels of different material formulations are extruded so as to be interlaced across an area, and then solidified (e.g., cured) to form an interlaced pattern of voxels of the solidified material, with the interlacing oriented in multiple directions.

[0096] Digital modeling materials may exhibit novel properties influenced by the selection of material formulation types and / or the ratios and relative spatial distributions of two or more material formulations.

[0097] As used herein, a "voxel" of a layer refers to a physical three-dimensional elementary volume within that layer, corresponding to a single pixel of the bitmap describing that layer. The size of a voxel is approximately the size of the area formed by the construction material after it has been extruded, leveled, and solidified at the location corresponding to each pixel.

[0098] This embodiment therefore enables the extrusion of a wide range of material formulation combinations and the molding of an object into different parts of an object, which may consist of multiple different combinations of material formulations according to desired properties for characterizing each part of the object.

[0099] Further details regarding the principles and operation of an AM system suitable for this embodiment can be found in U.S. Patent No. 9,031,680 and International Publication No. WO2022 / 024114, the contents of which are incorporated herein by reference.

[0100] In some embodiments of the present invention, system 10 and / or system 110 are configured to print one or more objects onto a fabric.

[0101] As used herein, “fabric” encompasses any product made from at least partially natural and synthetic fibrous materials. Examples of types of fabric include, but are not limited to, clothing, shoes, toys, textile products, carpets, textile hats, textile bags, socks, towels, and curtains.

[0102] This embodiment is intended for printing on woven or nonwoven fabrics.

[0103] As used herein, “woven” means a structure produced when at least two sets of twisted yarns are woven together according to a predetermined weaving pattern, for example, perpendicular to each other, in accordance with ASTM D123-03, such that at least one set is parallel to the axis along the longitudinal direction of the fabric.

[0104] As used herein, the term "nonwoven" means a textile structure produced by joining or bonding fabrics, or both, completed by mechanical, chemical, thermal, or solvent means, in accordance with ASTM D123-03.

[0105] Preferably, but not necessarily, when the printing system (e.g., system 10 or 110) is employed to print an object onto a fabric, the leveling device 32 is not used for at least some of the layers. In these embodiments, each layer of construction material extruded onto the fabric is solidified (e.g., cured) after extrusion without leveling the layers.

[0106] Preferably, but not necessarily, when a printing system (e.g., system 10 or 110) is employed to print an object on a fabric, the height of the object to be printed is less than 10 cm, more preferably less than 9 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 more preferably less than 1 cm.

[0107] In some embodiments of the present invention, the process for forming a three-dimensional object on a fabric includes the step of extruding one or more layers of a material onto the fabric, and the object is formed on the layers of material. The material acts alone or in combination with a fabric pretreatment process (e.g., chemical, thermal, and / or mechanical treatment) to ensure adhesion between the fabric and the object. In some embodiments of the present invention, the material may be a modeling material, such as Vero® and / or VeroUltra® Clear, which, when cured, is relatively hard and rigid. Additional materials contemplated include, but are not limited to, VeroFlex® and VeroEco®Flex, which are sold by Stratasys Ltd.

[0108] Conventional AM systems enable the printing of 3D objects based on computer object data prepared based on the 3D outline of each object. In such systems, the operator selects the outline of the object to be manufactured, for example, using appropriate software such as CAD software. This software then generates computer object data in the form of graphic elements that define the surface of the object (e.g., a polygon mesh, a non-uniform rational B-spline, etc.). These graphic elements are processed by a computer employing software known as a "slicer," which converts the graphic elements into a grid of voxels that define the internal shape of the object, and arranges them as multiple slices, each containing multiple voxels that describe layers of the 3D object.

[0109] The inventors have found that since it is easier to acquire or prepare a two-dimensional image compared to preparing a three-dimensional outline of an object, such a system can be significantly improved by enabling an operator to select a two-dimensional image. This embodiment therefore provides a design tool that enables an end user to select a two-dimensional image and, in accordance with such selection, generate computer object data that can be used by an AM system to shape a three-dimensional object corresponding to the selected two-dimensional image. The computer object data generated by the design tool can generally be stored in a computer-readable storage medium in the form of one or more computer files. In various exemplary embodiments of the present invention, the three-dimensional object described by the computer object data includes a plurality of individual protruding elements that collectively form a relief pattern, which is a three-dimensional representation of the image information contained within the selected two-dimensional image.

[0110] The protruding element structure of the molded object maintains the flexibility of the fabric, and the design tools are specifically used for shaping three-dimensional objects on fabric.

[0111] The design tool of this embodiment uses a graphical user interface (GUI) displayed by a computer, for example, a display device, for example, computer 24 on display device 25 of computer 24, or user interface 116. The GUI provides ease of use to the user interface between the end user of the AM system and the computer. The GUI includes a number of computer-generated objects called “GUI controls,” or more simply, “controls.” Some GUI controls may be grouped together as a set, called a “control set.” A control set generally includes two or more GUI controls, but the following references to “control sets” also include specific cases in which a control set includes a single GUI control. Typical examples of GUI controls suitable for this embodiment include, but are not limited to, sliders, drop-down menus, combo boxes, text boxes, switch buttons, knob selectors, and the like.

[0112] GUI control operates through dedicated software and responds to physical actions performed by the user via a device that communicates signals to the computer. Such a device may be a computer mouse, touchscreen, keyboard, etc., and may optionally include a microphone, in which case the computer is configured to run voice activation software. The GUI may optionally, preferably, display additional information, such as non-interactive text and graphics.

[0113] During operation, the end user may select and activate controls to initiate actions that will be performed by the computer's processor. The software operating the GUI sends activation signals to the processor, for example, by I / O circuitry configured to communicate signals between the GUI and the processor. Activation signals may be sent to the processor either when each control is activated, or at a later point (for example, when another control is activated). Controls are optionally, preferably, displayed on the GUI as graphical elements marked to indicate actions that the processor will perform in response to the activation of these controls. Controls may be arranged in a predetermined layout, or may be dynamically created and / or deleted in response to specific actions taken by the end user by other GUI controls. For example, the user may select buttons to open or close another control, expand a control, display an image, and / or switch between GUI layouts (often called GUI screens or tabs, etc.).

[0114] The GUI of this embodiment receives input from the end user via GUI control relating to one or more two-dimensional images, and optionally, preferably, to one or more characteristics of protruding elements for forming a relief pattern that represents the image information on the two-dimensional images. In response to the activation of one or more GUI controls, the computer's I / O circuits communicate signals relating to these inputs from the GUI to the processor, and the processor converts these inputs into computer object data describing the relief pattern. The processor stores the computer object data in a computer-readable storage medium.

[0115] Typical examples of GUI400 suitable for this embodiment are shown in Figures 4A to 4E. GUI400 comprises multiple control sets, as will be further detailed below. In exemplary embodiments, which should not be considered limiting, the control sets are arranged within multiple screens, indicated in Figures 4A to 4E as "Screen 1," "Screen 2," "Screen 3," and so on. The multiple screens may be displayed simultaneously (for example, side by side) or sequentially, in which case GUI400 may include one or more screen selectors 402 to allow an end user to command GUI400 which screen to display.

[0116] The GUI 400 includes an image selection control set 404, as shown in Figure 4A. In a typical example, the image selection control set 404 is displayed within "Screen 1" of the GUI 400. The control set 404 allows the user to select a two-dimensional image stored in a computer-readable medium. In some embodiments of the present invention, the user is made able to select two or more two-dimensional images. Generally, the control set 404 includes a text box or browsing control 406 that allows the user to type or select the address of an image. The control set 404 may include an image preview area 416 where the selected image is displayed. The control set 404 may optionally, preferably, include a control 408 that allows the user to input the physical dimensions of a three-dimensional object to be molded. Preferably, the control set 404 includes a control 410, such as a drop-down menu, that allows the user to select an AM system for molding the object. In these embodiments, the GUI 400 is configured to warn the user when the dimensions entered in the control 408 exceed the dimensions of a tray (e.g., tray 12) of a particular AM system. Optionally, GUI400 prevents users from entering dimensions that exceed the tray dimensions. However, this is not always necessary, as in some application examples, it may be beneficial to allow the design of larger objects that can be manufactured in segments by the AM system.

[0117] The image selection control set 404 may also include a geometric operation control 412 that enables multiple image manipulation controls, such as rotation, flipping, and / or mirroring, and a masking operation control 414 that enables masking of an image based on color or gray level, or according to an input pattern or drawing.

[0118] Once an image is selected by control 406, the processor may optionally, preferably, identify background areas 418 and non-background areas 419 within the image. This can be done 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, and the like. Alternatively, depending on the format of the image data contained within the two-dimensional image, the background may be identified by one or more specific channels of the image data. For example, image data in the form of Portable Network Graphics (PNG) includes an alpha channel that can be used to identify the background of the image. Identification of the background areas 418 and non-background areas 419 may occur immediately upon loading the image data, or it may occur in response to the activation of background identification control 417.

[0119] GUI400 may include a tiling selection control set 420, as shown in Figure 4B. In a typical example, the tiling selection control set 420 is displayed within "Screen 2" of GUI400. The control set 420 allows the user to select a tiling pattern 426. Based on the selected tiling pattern 426, the processor defines a number of separate tiling elements 422, each associated with a different local portion of image data contained within a two-dimensional image. When two or more images are selected by the control set 404, all tiling elements 422 are preferably associated with each portion of image data contained within one of the selected two-dimensional images. Preferably, the tiling pattern 426 is defined only on the non-background areas of the image. Preferably, the tiling pattern 426 substantially traces the contour of the two-dimensional image.

[0120] The control set 420 optionally includes one or more tiling pattern preview areas 424 on which a preview of the selected tiling pattern 426 or a portion thereof is displayed. The selection of the tiling pattern 426 can be performed in two or more ways. In some embodiments of the present invention, the control set 420 includes controls 428, 430, 432 for each tiling element 422 to optionally, preferably individually, select the shape (control 428) and size or equivalent density (control 430), and optionally, preferably the spacing between adjacent tiling elements 422 (control 432). Optionally, the tiling selection control set 420 allows the user to select different sizes for different tiling elements and / or different spacings between different pairs of tiling elements.

[0121] In some embodiments of the present invention, the tiling selection control set 420 allows the user to load one or more maps containing information about the shape, size (or equivalent density), and / or spacing of tiling elements 422 across a two-dimensional image. In these embodiments, the processor selects one or more of the characteristics of the elements 422 based on the information in each map.

[0122] Typical examples of the shapes of the tiling elements 422 that can be selected by the control set 420 in any of the embodiments described above include, but are not limited to, polygons (e.g., triangular, pentagonal, hexagonal, octagonal, and quadrilateral polygons, e.g., rectangles), circles, ellipses, and the like. Preferably, but not necessarily, the shape is convex. When the shape is a polygon, it is optionally, preferably, a normal polygon.

[0123] Two-dimensional tiling using tiling pattern 426 may be any image processing technique known in the art. In a typical example of such a procedure, the two-dimensional image is divided into superpixels by applying a commercially available image processing function, such as, but not limited to, the “superpixels” function available in Matlab® software. Each superpixel is represented by a single point, in this case by applying a reduction function to the superpixel, for example. A suitable reduction function is commercially available as one of the options within the bwmorph function of Matlab® software. A Voronoi diagram is then constructed from the acquired single points, thereby tiling the two-dimensional image. The advantage of this procedure is that it provides a tiling pattern that traces the two-dimensional contour. Another preferred technique for forming a tiling pattern that traces the two-dimensional contour involves dividing one or more of the superpixels into convex polygons. This may be done by any commercially available image processing function, such as, but not limited to, the “coverageDecomposition” function of the UAV Toolbok in Matlab® software. Combinations of the above procedures are also considered. In some embodiments of the present invention, the location of a point is perturbed by a quantity that depends on one or more features of the two-dimensional image. For example, a point located within a range of small standard deviations in the image values ​​may be perturbed by a large quantity.

[0124] The two-dimensional tiling by the tiling pattern 426 may, as an alternative or addition, be based on image data of the two-dimensional image itself. A typical example of an image processing procedure suitable for this embodiment is as follows: A map of values ​​is created based on the image data. Such a map associates specific values ​​with each pixel of the image, based on the color, hue, gray label, or contrast of the pixels, or based on the distance between pixels in the image, as is known in the art. Once the map of values ​​is created, a gradient across the map is calculated using the map values. The map values ​​and gradient are then used to form a vector field having a number of individual vectors. For example, the direction of the vectors in the field may define the gradient, and the length of the vectors may define the map values. The vector field undergoes a geometric transformation that converts the individual vectors into a grid of a given geometry. The geometry optionally, preferably, corresponds to the shape of the tiling elements selected by the control set 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. In this case, the grid cells are defined as tiling elements 422.

[0125] GUI400 may include a relief selection control set 440, as shown in Figure 4C. In a typical example, the relief selection control set 440 is displayed within "Screen 3" of GUI400. The control set 440 allows the user to select a three-dimensional shape for protruding elements 450 that form a relief pattern 458, which is a three-dimensional representation of the image information contained within the selected two-dimensional image, as described above. Each protruding element 450 protrudes outward from one of the tiling elements, and therefore each tiling element serves as the base of the protruding element 450. Each protruding element 450 has one or more intensity levels, depending on the different parts of the image data (for example, the parts associated with each tiling element). The intensity levels of the protruding elements may be the gray levels of the tiling elements, or a set of intensity levels that collectively define the color of the tiling elements by a color coordinate system.

[0126] In embodiments where two images are selected, the intensity levels in different segments of a protruding element are optionally, preferably, selected based on different images. For example, the intensity level at the bottom of the protruding element may be based on one of the images, and the intensity level at the top of the protruding element may be based on the other image. This can be conveniently achieved by setting h such that the intensity level at all points of the protruding element having vertical coordinates less than a given vertical location threshold h is based on one of the images, and the intensity level at all other points of the protruding element is based on the other image. The inventors unexpectedly found that the selection of intensity levels in different segments of a protruding element based on different images creates a lenticular-like illusion to the molded relief pattern, and therefore provides views of different images when the same relief pattern is viewed from different viewing directions.

[0127] The overall height of the protruding elements 450 may be uniform or non-uniform across the image. The control set 440 optionally, preferably includes a preview of the selected protruding elements 450 and a preview area 442 on which the relief pattern 458 is displayed. In some embodiments, the preview of the relief pattern 458 is displayed by different control sets (for example, in different screens of the GUI 400) as an alternative or additional display.

[0128] In the simplest implementation of GUI400, control set 440 automatically selects the three-dimensional shape and size of each of the protruding elements 450. For example, control set 440 may select a dome shape and uniform height for the protruding elements 450. In some embodiments of the present invention, control set 440 may include a shape selector 442 that provides the user with a list of shape options for selection, for example, in the form of a drop-down menu. Representative examples of three-dimensional shapes suitable for this embodiment are shown in Figures 5A to 5F and include, but are not limited to, a cone (Figure 5A), a dome (Figure 5B), a hemisphere (Figure 5C), a chamfer (Figure 5D), a fillet (Figure 5E), and a right cylinder (Figure 5F). The shapes shown in Figures 5A to 5F have a circular base and are therefore suitable when each tiling element is circular. Those skilled in the art will know how to modify Figures 5A to 5F for other shapes of tiling elements once the details described herein are provided. In some embodiments of the present invention, the shape selector 442 selects a shape for the entire protruding element, and in some embodiments of the present invention, the shape selector 442 selects a shape for only the upper part of the protruding element, with the rest of the protruding element being a right-side extrusion of the shape of the respective tiling element.

[0129] Referring again to Figure 4C, the control set 440 may optionally, preferably, include a height selector 444 (shown as a slider in the simplified example) for selecting the height of each protrusion element (if a uniform height is adopted) or the maximum allowable height for a protrusion element. In some embodiments of the present invention, the control set 440 also includes a minimum height selector 446 (also shown as a slider in the simplified example) for selecting the minimum height of a protrusion element. When the heights of the protrusion elements are non-uniform across the two-dimensional image, all protrusion elements have a height that is at least the minimum height selected by control 446 and the maximum height selected by control 444.

[0130] The cross-sectional size of the projection elements 450 may be the same throughout their length, or the cross-sectional size may differ along at least one segment of the projection element 450. Generally, at the base of the projection element, the cross-sectional size is determined by the size of each tiling element, and in other parts of the projection element, the cross-sectional size is the same at the base or changes monotonically with respect to the distance from the base, as shown in Figure 4C. Also intended is an embodiment in which control set 440 comprises a cross-sectional size selector (not shown), which may replace control 430 of control set 420.

[0131] The spacing between the protruding elements 450 is generally determined by the spacing between adjacent tiling elements. Another embodiment is envisioned in which control set 440 includes a spacing selector (not shown) which may replace control 432 of control set 420.

[0132] When the heights of the protruding elements are non-uniform, the control set 440 can select the heights in two or more ways. In some embodiments of the present invention, the control set 440 selects the height of each individual protruding element based on the portion of image data associated with each tiling element. For example, the selection may be based on a rule that takes the color or hue or gray level of the image data as input and provides the height of each protruding element based on that input. Thus, in these embodiments, the processor reads the image data for each tiling element and uses the rule to select the height of the protruding element that will protrude outward from that tiling element. As a non-limiting example, the rule may be such that the protruding element is taller relative to darker areas in the image and shorter relative to brighter areas in the image. The control set 440 may include a height rule selector 448 that allows a user to select a rule that the image data will use to define the height of the protruding elements accordingly.

[0133] For example, the height rule selector 448 could allow selection from options such as assigning higher protrusions to darker areas, assigning higher protrusions to brighter areas, assigning higher protrusions to red areas, assigning higher protrusions to green areas, assigning higher protrusions to blue areas, assigning higher protrusions to yellow areas, and so on.

[0134] In some embodiments of the present invention, the height rule selector 448 includes an option for selecting the height of each individual protrusion element based on a height map. The height map preferably associates each tiling element of a tiling pattern with the height of a protrusion element, and the control set 440 may set the height of each protrusion element 450 based on the height values ​​stored in the map for each tiling element. The height map may be generated in response to user input or automatically, or the height map may be loaded from a computer-readable medium. A typical example of a control set suitable for enabling a processor to generate a height map is provided below.

[0135] The relief selection control set 440 may also include a finesse selector 452 to allow the user to select the finesse of the protruding element. Generally, based on the selected finesse, the processor defines the tessellation resolution in the curved portion of the protruding element. Figures 7A and 7B show the preview area 442 with respect to two exemplary values ​​entered into the finesse selector 452, where the finesse value is higher with respect to Figure 7A than with respect to Figure 7B.

[0136] The relief selection control set 440 may also include a transparency control 454 that allows the user to select whether and to what extent to mold the protruding elements using transparent construction material. Generally, though not always, during AM molding, the selected transparency is applied only to the top of the protruding elements.

[0137] The term "transparent" describes a material property that reflects the transmittance of light passing through it. A transparent material is generally characterized as being able to transmit at least 70% of the light passing through it, or with a transmittance of at least 70%. The transmittance of a material can be determined using methods well known in the art.

[0138] Representative examples of modeling materials suitable for forming transparent protruding elements include, but are not limited to, materials with the trademark names RGD720, MED610®, MED625FLX®, and VeroClear®, all commercially available from Stratasys Ltd., Israel. Additional transparent modeling materials are described in International Publications WO2020 / 065654 and WO2021 / 014434. During AM of protruding elements, the transparency level of the protruding elements can be controlled by a careful selection of the ratio between opaque and transparent materials in the digital material forming the protruding elements.

[0139] The relief selection control set 440 may also include a severity selection control 456. Generally, based on the selected severity, the processor defines the curvature of the curved portion of the protruding element. Figures 8A and 8B show the preview area 442 for two exemplary values ​​entered into the severity selector 456, where the severity value is higher with respect to Figure 8A than with respect to Figure 8B.

[0140] GUI400 may also include a lenticularization control set 460, as shown in Figure 4D. In a typical example, the lenticularization control set 460 is displayed within “Screen 4” of GUI400. The control set 460 also allows the user to choose whether or not to apply lenticularization, and optionally, preferably, to choose a lenticularization method. Lenticularization is performed by shaping the top of a protruding element into a lens (e.g., formed as a dome or hemisphere), coloring their bases with multiple colors so that light beams of different colors are drawn back in different directions by the lens, and creating the illusion that the image represented by the shaped relief pattern changes when viewed from different directions. This can be achieved by a firm selection of at least one of the shape, color, and transparency level of the protruding element 450. The control set 460 may also include a lenticularization preview area 470 that provides a view of the selected image after lenticularization has been applied. In some embodiments of the present invention, the control set 460 includes a preview switch 468, and when the switch 468 is activated, the preview area 470 displays the image after lenticularization, and when the switch 468 is deactivated, the preview area 470 displays the image before lenticularization.

[0141] The control set 460 preferably includes a lenticular activation button 462 and an indicator 464 that is highlighted when the button 462 is activated. When the button is activated, the processor may automatically select a lenticularization scheme. The lenticularization scheme may include at least one of the following: the color of the tiling elements that serve as the base of the protruding elements, the focal length of the lenses that form the top of the protruding elements, and the transparency level of the protruding elements.

[0142] In some embodiments of the present invention, the control set 460 allows the user to select a lenticularization scheme. Generally, the control set 460 includes a color selector 464, which allows the user to select a base color. The user can select two or more colors individually, or select a single color, in which case the GUI 400 automatically selects one or more other colors (for example, inverted colors in the case of a two-color scheme, or a triad in the case of a three-color scheme) based on a predetermined color scheme. Also intended is an embodiment in which the GUI 400 automatically selects a color based on the color of the tiling element itself.

[0143] For example, when a two-color scheme is used, GUI400 splits each tiling element into two regions: the first region is colored using the original color of the input 2D image at the location of the tiling element, and the second region is colored using a color that is the inverse of the color of the first region. Similarly, when a three-color scheme is used, GUI400 splits each tiling element into three regions: the first region is colored using the color of the input 2D image at the location of the tiling element, and the second and third regions are each colored using colors that form a triad set using the color of the first region.

[0144] The control set 460 includes a lenticular intensity selector 466, which allows the user to select the intensity of lenticularization. The intensity selected by the user can be used by the processor 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 protruding element.

[0145] Any of the above properties of the relief pattern that generates the object may be non-uniform across the object. Such non-uniformity can be achieved by using one or more maps that locally assign each property across the image. For example, if it is desired that the height of the protrusions be non-uniform across the object, the processor may use a height map to select the height; if it is desired that the density of the protrusions be non-uniform across the object, the processor may use a density map to select the height; if it is desired that the cross-sectional size of the protrusions be non-uniform across the object, the processor may use a size map to select the cross-sectional size; if it is desired that the shape of the base of the protrusions (or equivalently the shape of the tiling elements) be non-uniform across the object, the processor may use a shape map to select the shape; if it is desired that the spacing between the protrusions be non-uniform across the object, the processor may use a spacing map to select the spacing between the protrusions; and if it is desired that the lenticularization scheme be non-uniform across the object, the processor may use a lenticularization map to select the lenticularization scheme.

[0146] One or more maps can be loaded from a computer-readable storage medium, or they can be generated based on user selection, for example, by a map generation control set. A typical example of a map generation control set 480 is shown in Figure 4E. In the typical example, the map generation control set 480 is displayed within “screen 5” of the GUI 400. The control set 480 includes an image preview area 482, which may be similar to the area 416 described above, except that it optionally, preferably, allows the user to mark points or regions 484 on the image. The control set 480 may also include a local characteristic selection control 486, which is shown as a slider in the simplified example, but may be embodied as any other type of selector. The control 486 allows the user to separately select each characteristic for each individual point 484. For example, when the control set 480 is used to generate a height map, the control 486 allows the user to separately select the height with respect to a protruding element for each individual point 484. GUI400 may have different sets of controls 480 for generating different maps, or GUI400 may display a map type selection control 488 that allows the user to select for which characteristics a map is generated. When a map type is selected, the label 490 of control 486 is changed accordingly. For example, in the illustrated example, the height map is selected, and therefore the label 490 indicates "local height".

[0147] When the map creation control 492 is activated, the processor generates a map for each tiling element across the tiling pattern, for example, using an interpolation algorithm, based on the local values ​​assigned to each of the points 484. For non-numerical properties (e.g., the shape of the tiling elements), the processor may utilize a proximity procedure to assign local values ​​for each property based on its proximity to one or more of the points 484. Optionally, and preferably, the created maps are displayed in the image preview area 482, as illustrated in Figure 4F.

[0148] Figure 6 is a flowchart illustrating a suitable method for generating computer object data for additive manufacturing according to several 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 when additive manufacturing involves three-dimensional printing on fabric, and is particularly useful when additive manufacturing involves three-dimensional inkjet printing on fabric.

[0149] Computer programs implementing this method may be delivered to users on distributed media, including, but not limited to, flash memory, CD-ROMs, or remote media that communicate with a local computer over the internet. From the distributed media, the computer programs may be copied to a hard disk or similar intermediate storage medium. The computer programs may be executed by loading computer instructions, which configure the computer to operate according to this method, into the computer's executable memory from either of those distributed media or those intermediate storage mediums. All of these operations are well known to those skilled in the art of computer systems.

[0150] This method can be embodied in many forms. For example, this method can be embodied on a tangible medium, such as a computer for carrying out the method steps. This method can be embodied on a computer-readable medium equipped with computer-readable instructions for performing the method steps. This method can also be embodied in an electronic device having digital computer capabilities arranged to run a computer program on a tangible medium or to execute instructions on a computer-readable medium.

[0151] The method of this embodiment may be performed by a data processor that operates an AM system (e.g., computer 24). The computer object data processed by this method may be transmitted to a controller of the AM system (e.g., controller 20). The processed computer object data may be transmitted in whole before the AM processing begins, or in batches (e.g., in slice units) if the AM process begins after the first batch arrives but before the last batch is received. Alternatively, the method of this embodiment may be performed by a controller of the AM system (e.g., controller 20). In these embodiments, the controller receives input data and uses this input data to perform this method. The input data may be received by the controller before the AM process begins, or in batches if the AM process begins after the first batch arrives but before the last batch is received.

[0152] This method begins at 600 and optionally, preferably, proceeds to 601, where a GUI such as GUI400 is displayed (but is not limited to this). This method proceeds to 602, where image data describing a two-dimensional image selected by the GUI (for example, via image selection control set 404) is loaded. In some embodiments of the present invention, this method proceeds to 603, where background and non-background areas are identified in the image, as will be further detailed below.

[0153] This method proceeds to 604, where individual tiling elements (e.g., element 422) are defined based on a tiling pattern (e.g., pattern 426) selected by the GUI (e.g., via the tiling selection control set 420), as will be further detailed below. Preferably, the tiling is applied only to the non-background areas of the image. This method optionally, preferably, proceeds to 605, where one or more maps are generated that define local properties for the protruding elements forming the relief pattern, as will be further detailed below. Alternatively or additionally, this method may proceed to 606, where the properties of the protruding elements are selected non-locally. Preferably, operations 605 and 606 are applied to different properties.

[0154] In some embodiments of the present invention, the method proceeds to 607, where a lenticularization scheme is selected by a GUI (for example, via a lenticularization control set 460). Depending on the selected scheme, one or more of the characteristics of the protruding elements (for example, the color of the tiling elements, the shape of the top of the protruding elements, and the transparency of the protruding elements) are preferably adjusted according to the lenticularization scheme.

[0155] The method proceeds to 608, where a three-dimensional image including individual protruding elements (e.g., protruding element 450 of relief pattern 458) that extend beyond the tiling elements (e.g., element 422) is displayed on the GUI, as will be further detailed below. The method proceeds to 609, where computer object data describing the protruding elements is generated and stored in computer storage. The computer object data may be in any of the aforementioned formats and can be generated by exporting a three-dimensional image of a protruding element known in the art.

[0156] In some embodiments of the present invention, the method proceeds to 609, where the computer object data is sliced ​​to provide slice data that describes one of the layers of the object to be manufactured, each describing a plurality of slices defined for a plurality of voxels. The slicing operation 609 preferably assigns construction material to each voxel in each slice according to the characteristics of the protruding elements to traverse the corresponding layer. The slice data may be generated by the same software that operates the GUI, or the slice data may be generated by running slicer software that is independent of the software that operates the GUI.

[0157] In operation 610, slice data describing the slices and their respective build material assignments is sent to the additive manufacturing system's controller (e.g., controller 20). The controller (e.g., controller 20) sends control signals to the AM system for forming the layers corresponding to each slice. Preferably, the layers are formed on a fabric, in which case the fabric is placed on a tray (e.g., tray 12) of the AM system before triggering operation 610.

[0158] This method terminates at 611.

[0159] As used herein, the term "approximately" refers to + / - 10%.

[0160] The terms "comprises," "comprising," "includes," "including," and "having," and their conjugations, all mean "to include, but not limit."

[0161] The term "consisting of" means "including but not limiting."

[0162] The term "essentially consisting of" means that the composition, method, or structure may include additional components, steps, and / or parts, but those additional components, steps, and / or parts do not materially alter the basic and novel properties of the claimed composition, method, or structure.

[0163] Unless otherwise specified, the singular forms "a," "an," and "the" as used herein include the plural forms. For example, the terms "compound" or "at least one compound" may include multiple compounds, including mixtures thereof.

[0164] Throughout this application, various embodiments of the present invention may be presented in range format. It should be understood that the range format description is for convenience and brevity only and should not be interpreted as an inflexible limitation on the scope of the invention. Therefore, the range description should be considered to specifically disclose all possible subranges, as well as the individual numerical values ​​within those ranges. For example, a range description such as 1 to 6 should be considered to specifically disclose subranges such as 1 to 3, 1 to 4, 1 to 5, 2 to 4, 2 to 6, 3 to 6, etc., as well as the individual numerical values ​​within those ranges, such as 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

[0165] Whenever a numerical range is indicated herein, it means that it includes any stated number (decimal or integer) within the indicated range. The phrases “range between” the first and second indicated numbers and “range from” the first indicated number to the second indicated number are used interchangeably herein and mean that they include the first and second indicated numbers, as well as all decimals and integers between them.

[0166] For clarity, it should be understood that some features of the present invention described in the context of separate embodiments may also be provided in combination with a single embodiment. Conversely, for clarity, various features of the present invention described in the context of a single embodiment may also be provided separately, in any preferred partial combination, or as suitable for any other described embodiment of the present invention. Some features described in the context of different embodiments should not be considered essential features of those embodiments unless those embodiments are inoperable without those elements.

[0167] While the present invention has been described in relation to its specific embodiments, it will be apparent that many modifications, alterations, and variations are obvious to those skilled in the art. Therefore, it is intended to encompass all such modifications, alterations, and variations that are included in the spirit and broad scope of the appended claims.

[0168] All publications, patents, and patent applications referenced herein are incorporated by reference in their entirety, as if each individual publication, patent, or patent application were specifically and individually referred to, when mentioned herein. In addition, any citation and identification of any reference in this application should not be construed as an acknowledgment that such reference is available as prior art to the present invention. To the extent that the heading of that section is used, these should not necessarily be construed as limiting. In addition, any priority document of this application is incorporated by reference in its entirety. [Explanation of Symbols]

[0169] 10 Systems 12 trays 14 vertical axis, axis 16. Discharge unit, unit, inkjet print head, head, print head 16a~16d Printhead, Head 18 Solidification devices 20 controllers 22 Nozzle arrays, one or more nozzle arrays 24. Computers, host computers 25 Displays, Display Devices 26 Work Area 28 Vertical Drives 30 Stabilizing structure 32 Leveling devices 34 Axis of Symmetry, Axis 36 Tray Replacement Devices 38 Drive 40 movable arms 42 Fluid material compounding supply system, supply system, construction material supply system 44. Fluid material container or cartridge 110 System 112 Objects, 3D Objects 114 Additive manufacturing apparatus, apparatus, molding apparatus 116 User Interface 121 Orifice Plate 124 Fluid construction material formulation 128 frames or blocks 134 Cooling System 136 Unwanted item collection device 326 Rollers 328 Radiation Source 400 GUI 402 Screen Selector 404 Image selection control set, control set 406 Text box or browsing control, control 408 Control 410 Control 412 Geometric Operation Control 414 Masking Operation Control 416 Image preview area, area 418 Background area, background 419 Non-background area, non-background 420 Tiling Selection Control Set, Control Set 422 tiling elements, elements 424 Tiling pattern preview area 426 tiling patterns, patterns 428 Control 430 Control 432 Control 440 Relief Selection Control Set, Control Set 442 Preview Area, Shape Selector 444 Height selector, control 446 Minimum height selector, control 448 Height Rule Selector 450 Projection element 452 Finesse Selector 454 Transparency control 456 Severity selection control, Severity selector 458 Relief Patterns 460 Lenticular Control Set, Control Set 462 Lenticular activation button, button 464 indicators, color selectors, selectors 466 Lenticularization Intensity Selector 468 Preview Switch, Switch 470 Lenticular preview area, preview area 480 Map generation control set, control set 482 Image preview area 484 points or areas 486 Local characteristic selection control, control 488 Map Type Selection Control 490 labels 492 Map creation control 609 Slicing operation

Claims

1. A method for generating computer object data for additive manufacturing, The steps include displaying a graphical user interface (GUI) having an image selection control set, a tiling selection control set, and a relief selection control set, The steps include loading image data describing the two-dimensional image selected by the aforementioned image selection control set, The steps include defining a plurality of separate tiling elements, each relating to a different portion of the image data, based on the tiling pattern selected by the tiling control set, A step of displaying a three-dimensional image on the GUI, each including a plurality of individual protruding elements that extend beyond the tiling elements of the tiling pattern, wherein each protruding element has a three-dimensional shape selected by the relief selection control set, and at least one segment of each protruding element has at least one intensity level corresponding to each portion of the image data; The steps include generating computer object data describing the aforementioned protruding element and storing the computer object data in computer storage. Methods that include...

2. The method according to claim 1, comprising the step of identifying background areas and non-background areas in the image, wherein the individual tiling elements tile only the non-background areas.

3. The method according to any one of claims 1 and 2, wherein the tiling selection control set is configured to allow a user to independently select the shape of the tiling elements and the spacing between the tiling elements.

4. The method according to any one of claims 1 to 3, wherein the tiling selection control set is configured to allow the user to independently select the size of the tiling elements.

5. The method according to any one of claims 1 to 4, wherein the tiling selection control set is configured to allow a user to select different sizes for different tiling elements.

6. The method according to any one of claims 1 to 5, wherein the tiling selection control set is configured to allow a user to select different spacings between different pairs of tiling elements.

7. The method according to any one of claims 1 to 6, wherein the relief selection control set is configured to enable the user to select at least one of (i) different heights with respect to different protruding elements, (ii) different spacings between different pairs of protruding elements, and (iii) different cross-sectional sizes with respect to different protruding elements.

8. The method according to any one of claims 1 to 6, wherein the relief selection control set is configured to automatically select at least one of (i) different heights with respect to different protrusion elements, (ii) different spacings between different pairs of protrusion elements, and (iii) different cross-sectional sizes with respect to different protrusion elements.

9. The method according to any one of claims 1 to 8, wherein the relief selection control set is configured to select the height of the protruding element based on the respective portion of the image data.

10. The method according to any one of claims 1 to 8, comprising the step of loading image data describing an additional image, wherein with respect to at least one protruding element, the intensity levels of different segments of the protruding element are based on image data of different images.

11. The method according to any one of claims 1 to 10, wherein the GUI comprises a height map control set configured to generate or import a height map, and the relief selection control set is configured to select the height of the protruding element based on the height map.

12. The method according to any one of claims 1 to 11, wherein the GUI comprises a density map control set configured to generate or import a density map, and the relief selection control set is configured to select the density of the protruding elements based on the density map.

13. The method according to any one of claims 1 to 12, wherein the GUI comprises a size map control set configured to generate or import a size map, and the relief selection control set is configured to select the cross-sectional size of the protruding element based on the size map.

14. The method according to any one of claims 1 to 13, wherein the GUI comprises a lenticularization control set configured to allow a user to select a lenticularization scheme, and the shape, color, and transparency level of the protruding elements are selected based on the lenticularization scheme.

15. The method according to any one of claims 1 to 13, wherein the GUI comprises a lenticularization control set configured to allow a user to instruct the GUI to automatically select a lenticularization scheme, the shape, color, and transparency level of the protruding elements being selected based on the lenticularization scheme.

16. The method according to any one of claims 1 to 15, comprising the step of slicing the computer object data into a plurality of slices, each defined over a plurality of voxels, and storing the slices in computer storage.

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

18. A method of additive manufacturing, A step of performing the method described in any one of claims 1 to 15, The steps include loading the computer object data from the computer storage, The steps include slicing the aforementioned computer object data into multiple slices, each defined across multiple voxels, For each voxel in each slice, the steps include assigning construction material according to at least one strength level of each protruding element containing the voxel, The steps include transmitting the plurality of slices and their respective construction material assignments to the controller of the additive manufacturing system for additive manufacturing of a plurality of layers, each corresponding to the plurality of slices, and Methods that include...

19. A method of additive manufacturing, A step of carrying out the method according to claim 16, The steps include loading the slice from the computer storage, For each voxel in each slice, the steps include assigning construction material according to at least one strength level of each protruding element containing the voxel, The steps include transmitting the plurality of slices and their respective construction material assignments to the controller of the additive manufacturing system for additive manufacturing of a plurality of layers, each corresponding to the plurality of slices, and Methods that include...

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

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

Images