CAD Object Splitting for Additive Manufacturing Efficiency
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Solution Overview
Problem
Current CAD software limitations in manufacturing efficiency, particularly in additive and subtractive processes, restrict the ability to optimize complex designs for cost-effective production and structural integrity, as they often require single manufacturing techniques and lack automation for splitting objects into more manageable parts.
Innovation Solution
The implementation of an object splitting design process within CAD software that determines a parting surface to split an initial object into separate components, allowing these components to be manufactured using various techniques such as additive, subtractive, or die casting, and then assembled, optimizing manufacturing efficiency and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an object is manufactured as a single piece using traditional CAD software, then structural integrity is maintained, but manufacturing efficiency and cost-effectiveness deteriorate due to limitations in additive and subtractive processes
Solution Approach 1:
The patent applies segmentation by automatically dividing a single complex object into multiple simpler components that can be manufactured separately using different additive or subtractive processes. The software analyzes the object's geometry and identifies optimal split locations, creating multiple manufacturable parts that can be produced more efficiently than a monolithic structure.
2Adaptability or versatility
If CAD software supports multiple manufacturing techniques, then manufacturing flexibility improves, but the ability to optimize complex designs for cost-effective production deteriorates due to lack of automation in splitting objects
Solution Approach 1:
The patent implements self-service by enabling the CAD software to automatically perform the splitting operation without requiring manual intervention from the designer. The software autonomously analyzes the object, determines optimal division strategies, and generates separate component models ready for manufacturing, thereby automating a previously manual process.
3Loss of substance
If objects are split into separate components for manufacturing, then material usage and costs are reduced, but the complexity of assembling multiple parts increases
Solution Approach 1:
The patent applies preliminary action by pre-planning and pre-designing the assembly process during the splitting phase. The software not only divides the object but also automatically generates assembly instructions, defines connection interfaces, and optimizes the sequence of assembly operations, thereby resolving assembly complexity before manufacturing begins.
4Extent of automation
If traditional CAD software is used for generative design, then design automation improves, but the optimization of manufacturing efficiency deteriorates due to reliance on single manufacturing techniques
Solution Approach 1:
The patent implements universality by creating a multi-functional CAD system that integrates support for multiple manufacturing techniques (both additive and subtractive) within a single software environment. The system can evaluate different manufacturing approaches, compare their efficiency, and automatically select the optimal combination for each component, making the software adaptable to various production requirements.
Data Source
AI summary
Techniques and systems for computer aided design of physical structures using an object splitting design process that optimize manufacturing efficiency are described. A described technique includes splitting, by a computer program, a three dimensional model of an initial object into an up skin region and a down skin region based on an analysis of draft angles along at least one surface of the three dimensional model of the initial object. The technique further includes producing, by the computer program, first and second three dimensional models of respective first and second objects in accordance with the up skin region and the down skin region to create separate first and second physical structures using one or more computer-controlled manufacturing systems such that the first and second physical structures are combinable to form a combined physical structure.