Support Structures for Additive Manufacturing
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Solution Overview
Problem
Current commercial CAD/CAM systems lack sufficient functionality for creating support structures for additive manufacturing of solid models, leading to data translation issues, accuracy loss, and increased workflow complexity.
Innovation Solution
The system enables users to create and modify support structures directly within the CAD/CAM system using the User Defined Feature functionality, allowing for easy modification and archiving, and generates column supports on solid models by analyzing boundary representation surfaces to determine optimal support locations, minimizing contact with the part and facilitating easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If support structures are created outside the CAD/CAM system using data translation, then support structures can be generated for additive manufacturing, but data translation issues and accuracy loss occur
Solution Approach 1:
The patent merges the support structure creation functionality directly into the CAD/CAM system, eliminating the need for external tools and data translation. The support generator module integrates with the existing solid modeler, allowing users to create support structures within the same environment where part geometry is defined, thus preventing data accuracy loss and workflow complexity
Solution Approach 2:
The CAD/CAM system is enhanced with multi-functionality by incorporating the support structure generation capability alongside existing solid modeling and manufacturing operations. This universal system can now handle both part design and support creation without requiring separate specialized tools
2Ease of manufacture
If support structures are created outside the CAD/CAM system, then support structures can be generated, but workflow complexity increases
Solution Approach 1:
By combining support structure creation with the existing CAD/CAM workflow, the patent eliminates the need for separate external processes. Users can generate supports directly from solid models within the familiar CAD/CAM interface, maintaining ease of manufacture while reducing workflow complexity
3Manufacturing precision
If column supports are generated by analyzing b-rep surfaces, then accurate support locations are identified, but computational analysis is required
Solution Approach 1:
The system performs self-service by automatically analyzing the boundary representation surfaces of solid models to identify optimal support locations. The support generator module autonomously processes the geometric data, calculates appropriate support positions, and creates column supports without requiring manual intervention or external computational tools
Solution Approach 2:
The patent applies preliminary action by analyzing the solid model geometry before support structure creation. The system pre-processes the b-rep surfaces to identify potential support locations, ensuring accurate positioning of column supports before they are actually generated in the manufacturing workflow
Data Source
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AI summary
Systems and methods for support structures (604) for additive manufacturing of solid models (600). A method includes receiving (305) a solid model (600), for a physical object to be manufactured, that includes a plurality of boundary representation (b-rep) surfaces (620). The method includes analyzing (310) the b-rep surfaces (620) to generate point samples (624) for potential support locations (622). The method includes clustering (315) points on the solid model, corresponding to at least some of the point samples (624), to create support locations (622). The method includes generating (320) column supports (604) in the solid model that connect to the original solid model (600) at the support locations (622). The method includes storing (330) the solid model (600), including the column supports (604).