3D Model Intersection Workflow for Faster Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing methods require complex CAD modeling and lengthy programming times, especially when dealing with non-complex geometric elements, limiting their efficiency and flexibility in generating printing paths for additive manufacturing machines.
Innovation Solution
An additive manufacturing method that selects geometric entities from a library, intersects them with a basic 3D model to create an intermediate model, and then generates a working 3D model that excludes protruding portions, allowing for simplified 3D modeling and reduced programming time by using slicing software to produce a printing path for the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex CAD modeling is used to create accurate 3D models for slicing software, then manufacturing precision is improved, but programming time increases
Solution Approach 1:
The patent segments the 3D model creation process into two distinct phases: (1) creating a simplified basic 3D model using basic geometric shapes, and (2) adding geometric entities (stiffening ribs, filling portions, ventilation holes, lightening holes) that are automatically processed by the slicing software. This segmentation allows the modeler to work with simple geometries while the software handles the complex processing, thereby reducing programming time without sacrificing manufacturing precision.
Solution Approach 2:
The patent introduces an intermediary processing step where the slicing software automatically handles the geometric entities and generates the final printing path. Instead of manually modeling every detail in CAD software, the system uses an intermediary automated processing stage that takes the basic 3D model and geometric entities, processes them according to predefined rules, and generates the accurate working 3D model needed for manufacturing, thus bridging the gap between simple modeling and precise manufacturing.
2Manufacturing precision
If detailed geometric elements are modeled in CAD software, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the complex geometric processing tasks from the manual CAD modeling process and places them into the automated slicing software. Details such as stiffening ribs, filling portions, ventilation holes, and lightening holes are defined as separate geometric entities that are automatically processed by the software rather than being manually modeled in detail, thereby reducing CAD modeling complexity while maintaining manufacturing precision through automated processing.
3Adaptability or versatility
If complex geometric elements are used in 3D modeling, then adaptability is improved, but ease of manufacture worsens
Solution Approach 1:
The patent creates a universal system where a small set of basic geometric entities (stiffening ribs, filling portions, ventilation holes, lightening holes) can serve multiple functions and be applied to various basic 3D models. These geometric entities are defined with universal parameters and processing rules that allow them to be automatically adapted to different model types and requirements, providing high geometric flexibility and adaptability while maintaining ease of manufacture through standardized, automated processing.
Data Source
Figure 1A~1B
Figure 1C~2A
Figure 2B~2D
AI summary
An additive manufacturing method is disclosed that comprises the steps of storing a library of geometric entities, selecting a geometric entity and intersecting the geometric entity with a basic 3D model to obtain an intermediate 3D model that comprises a portion that is inside a volume of the basic 3D model and a protruding portion that protrudes beyond the aforesaid volume and which will not be considered to be a part to be printed, to obtain a working 3D model that is supplied to slicing software that converts the 3D working model into commands for a printing path of an additive manufacturing machine.