Deposition-Based Support Structure Generation via Convex Hull Offset
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Solution Overview
Problem
In deposition-based digital manufacturing systems, generating support structures for 3D models is inefficient due to the complexity and size of traditional support structures, which increase the time and difficulty in building, especially when moving the extrusion head around overhanging portions and filling interior regions.
Innovation Solution
A method is developed to generate support structures with convex outer dimensions that reduce in size and complexity downward, involving the creation of a convex hull polygon, offsetting its vertices inward and outward, and generating an intersection boundary polygon to produce tool paths that minimize the distance and angular deflection of the extrusion head, thereby reducing the size of interior voids and simplifying the build process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional support structures are used to support overhanging portions and cavities, then the 3D model can be built, but the time and difficulty in building increases due to the complexity and size of the support structures
Solution Approach 1:
The support structure generation process is segmented into multiple computational steps: generating initial support geometry, creating convex hull polygons, offsetting boundaries inward and outward, and generating intersection polygons. This segmentation allows each step to be optimized independently, reducing overall build time while maintaining support capability.
Solution Approach 2:
The patent changes the geometric parameters of support structures by applying convex hull algorithms and offset operations. By transforming the boundary polygons through mathematical operations (inward offset by distance d1, outward offset by distance d2), the support structure geometry is optimized to minimize extrusion head travel distance while maintaining adequate support function.
2Reliability
If traditional support structures with complex geometry are used, then adequate support is provided, but the distance and angular deflection of the extrusion head increases
Solution Approach 1:
The patent applies convex hull algorithms that transform complex polygonal boundaries into convex shapes with smoother transitions. This curvature optimization reduces the number of sharp angular deflections the extrusion head must make, thereby reducing movement complexity while maintaining the enclosing support volume necessary for structural support.
Solution Approach 2:
By applying offset operations with specific distances (inward offset d1, outward offset d2), the patent transforms the support structure geometry into optimized convex polygons. These parameter changes systematically reduce angular deflection requirements while preserving the support function through maintained volume enclosure.
3Reliability
If large support structures with extensive interior regions are built, then overhanging portions are adequately supported, but the time and difficulty in filling interior regions increases
Solution Approach 1:
The patent extracts and removes unnecessary interior regions from the support structure by applying inward offset operations. By offsetting the boundary polygon inward by distance d1, the method creates a reduced interior volume that maintains essential support coverage while eliminating excessive material that would require time-consuming filling operations.
Solution Approach 2:
The systematic application of offset distances (inward d1, outward d2) transforms the support structure to achieve optimal interior volume. This parameter-based approach reduces interior filling requirements while preserving the outward projection necessary for supporting overhanging model portions.
Data Source
AI summary
A method for generating data for a support structure to be built with a deposition-based digital manufacturing system, the method comprising generating a convex hull polygon based on a boundary polygon of a layer of the support structure, offsetting the convex hull polygon inward, offsetting the boundary polygon outward, and generating an intersection boundary polygon based at least in part on the offset boundary polygon and the offset convex hull polygon.