Generative 3D Design for 2.5-Axis Milling Tool Accessibility
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Solution Overview
Problem
Current CAD software lacks efficient methods to address non-manufacturable corners and cave-ins in 3D models designed for 2.5-axis subtractive manufacturing, which can lead to tool interference and reduced manufacturing efficiency.
Innovation Solution
A method that processes density-based representations of 3D models to identify and remove non-manufacturable corners and cave-ins by adjusting milling depths, ensuring tool accessibility without requiring boundary surface information, and optimizing the model for 2.5-axis machining by iteratively modifying the geometry and topology in accordance with the milling direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If generative design is used to create optimized 3D geometry, then design objectives such as minimizing weight are achieved, but non-manufacturable corners and cave-ins are created that cannot be processed by 2.5-axis subtractive manufacturing
Solution Approach 1:
The patent applies preliminary action by performing manufacturability checks during the generative design process itself, rather than after design completion. The system evaluates tool accessibility and identifies non-manufacturable features (corners and cave-ins) before finalizing the design, allowing corrections to be made proactively. This prevents the creation of features that would require complex multi-axis machining, enabling straightforward 2.5-axis manufacturing while preserving design optimization goals.
2Ease of operation
If traditional CAD software processes are used, then boundary surface information is available for manufacturing, but the software lacks efficient methods to identify and remove non-manufacturable features for 2.5-axis machining
Solution Approach 1:
The patent implements self-service by enabling the CAD software to automatically identify and remove non-manufacturable features without requiring manual intervention or external boundary surface information. The system autonomously performs manufacturability analysis, detects corners and cave-ins that cannot be accessed by 2.5-axis tools, and modifies the design accordingly. This self-diagnosing and self-correcting capability eliminates the need for additional software tools or manual processing steps, directly improving manufacturing efficiency.
3Device complexity
If 2.5-axis subtractive manufacturing is used, then manufacturing simplicity is maintained, but tool interference occurs when non-manufacturable features are present in the model
Solution Approach 1:
The patent applies preliminary anti-action by proactively preventing tool interference through design-stage modifications. The system identifies features that would cause tool interference (such as narrow cave-ins and sharp corners inaccessible to 2.5-axis tools) and modifies them before manufacturing begins. By anticipating and counteracting potential interference problems in advance, the system ensures reliable 2.5-axis manufacturing without requiring complex toolpaths or repositioning operations, maintaining both process simplicity and manufacturing reliability.
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design of physical structures include: obtaining a density-based representation of a modeled object, the density-based representation comprising multiple different subsets of elements, each subset having a starting element at a milling depth, which is one of three or more milling depths for three or more corresponding discrete layers that are each perpendicular to a milling direction for the modeled object; and reassigning milling depths of at least a portion of the multiple different subsets of elements, the reassigning for a current starting element in a current layer for an element subset comprising moving the milling depth for the element subset of the current starting element when an angular difference between other starting elements, which are associated with the current starting element and are located in a different layer, meets or exceeds a threshold value.