Boundary CAD Models for Editable 2.5-Axis Machining Geometry
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Solution Overview
Problem
Current CAD software limitations in generating 3D geometry for 2.5-axis subtractive manufacturing, as they often require manual intervention and are inefficient in handling discrete height layers and milling directions, leading to increased machining time and complexity.
Innovation Solution
A boundary-based generative design process that uses level-set methods to optimize topology, guiding shape changes towards discrete height layers suitable for 2.5-axis manufacturing, incorporating manufacturability constraints to facilitate efficient toolpath generation and reduce CAM programming time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If current CAD software generates 3D geometry for 2.5-axis subtractive manufacturing, then the design can be manufactured, but the process requires manual intervention and is inefficient
Solution Approach 1:
The system performs preliminary actions by automatically generating 3D geometry that is pre-constrained to be compatible with 2.5-axis subtractive manufacturing processes. The manufacturability constraints are applied during the generative design phase itself, rather than requiring post-processing or manual intervention later in the manufacturing preparation stage.
2Ease of manufacture
If manual intervention is used to handle discrete height layers and milling directions, then manufacturability is ensured, but machining time and complexity increase
Solution Approach 1:
The system implements self-service by automatically handling the discretization of height layers and determination of milling directions through the generative design process. The software autonomously generates geometry that inherently incorporates these manufacturing constraints, eliminating the need for manual intervention and reducing machining time.
3Ease of manufacture
If manual intervention is used to handle discrete height layers and milling directions, then manufacturability is ensured, but process complexity increases
Solution Approach 1:
The system merges the generative design process with manufacturability constraint enforcement into a single integrated workflow. By combining topology optimization with 2.5-axis manufacturing constraints (discrete height layers, milling directions) in the same computational framework, the system eliminates the need for separate manual processing steps, thereby reducing overall process complexity.
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design of physical structures using data format conversion (e.g., of output(s) from generative design processes) and user interface techniques that facilitate the production of 3D models of physical structures that are readily usable with 2.5-axis subtractive manufacturing, include: modifying smooth curves, which have been fit to contours representing discrete height layers of an object, to facilitate the 2.5-axis subtractive manufacturing; preparing an editable model of the object using a parametric feature history, which includes a sketch feature, to combine extruded versions of the smooth curves to form a 3D model of the object in a boundary representation format; reshaping a subset of the smooth curves responsive to user input with respect to the sketch feature; and replaying the parametric feature history to reconstruct the 3D model of the object, as changed by the user input.