3D Building Surface Panel Segmentation for Seamless Assembly

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Solution Overview

Problem

Existing methods for using solid surface materials in building surfaces, such as walls and ceilings, are labor-intensive, expensive, and difficult to install seamlessly due to the challenges of aligning and concealing seams, especially when featuring three-dimensional designs.

Innovation Solution

A method and system that automatically partitions a three-dimensional design into segments based on the dimensions of the building surface and the solid surface material units, generating milling instructions for cutting and assembling these segments to create a seamless, non-repeating design, which can be easily assembled by low-skilled workers without extensive sanding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If solid surface material is used for building surfaces with three-dimensional designs, then design versatility and surface complexity are improved, but installation difficulty and labor time increase significantly

Engineering Contradiction:

Improvedesign versatilityVSAvoidinstallation difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The building surface is divided into multiple modular panels that can be manufactured separately and assembled together. Each panel contains portions of the three-dimensional design, and the segmentation allows for standardized production while maintaining overall design complexity. The panels are designed with interlocking features that simplify assembly without compromising the three-dimensional surface effects.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The three-dimensional designs are pre-molded into the solid surface material during manufacturing, rather than requiring post-installation carving or shaping. Seam locations are pre-planned and incorporated into the panel designs, with complementary contours that will align when assembled. This preliminary preparation eliminates the need for expert installers to perform extensive sanding and alignment work on-site.

Inventive Principle:

Principle #10Preliminary action

2Shape

If solid surface material units are etched or contoured to include three-dimensional designs, then design complexity is improved, but seam alignment difficulty and visibility increase

Engineering Contradiction:

Improvethree-dimensional designVSAvoidseam alignment precision

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The panel designs incorporate asymmetric three-dimensional contours that are intentionally varied between panels. This asymmetry prevents obvious repeating patterns at seam lines and allows seams to be less visually prominent. The complementary asymmetric features on adjacent panels work together to create a unified three-dimensional surface when assembled, making individual panel boundaries less discernible.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The solution moves the alignment function from the two-dimensional plane to the third dimension by using vertical contours and relief features that extend above and below the panel surfaces. These three-dimensional features are designed to interlock or meet at complementary heights, creating visual continuity across seams. The depth variations and surface profiles provide alignment references that are more tolerant of minor positioning variations than flat surface markings would be.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Object-generated harmful factors

If expert installation with extensive sanding is performed to conceal seams, then seam visibility is reduced, but labor cost and installation time increase

Engineering Contradiction:

Improveseam visibilityVSAvoidinstallation speed

Core Design Contradiction:

Object-generated harmful factorsVSProductivity

Solution Approach 1:

The panel designs are self-aligning through complementary three-dimensional contours and interlocking features that guide proper positioning during assembly. The panels essentially install themselves into the correct positions without requiring expert measurement and alignment work. The design features automatically mask seam locations through their geometric relationships, eliminating the need for post-installation sanding or finishing work to conceal joints.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11625509B2Method of manufacturing complex three-dimensional building surfaces

Publication Date: 2023.04.11 3 PALMS GRP LLC

AI summary

A method implemented by a computer system, the computer-implemented method comprising receiving dimensions of a building surface, including a surface length and a surface height; receiving dimensions of a surface material unit, including a material length and a material height; receiving design parameters defining a three-dimensional design over the building surface; partitioning the three-dimensional design into a plurality of three-dimensional segments based on both the three-dimensional design and the dimensions of the surface material; and generating a set of milling instructions for cutting a plurality of surface material units into the plurality of three-dimensional segments.