Generative 3D Model Tool Size Control for 2.5-Axis Milling
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Solution Overview
Problem
Current CAD software limitations in generating 3D models for 2.5-axis subtractive manufacturing processes, as they often result in non-manufacturable corners and cave-ins, which are difficult to address without boundary surface information and can lead to inefficiencies in manufacturing.
Innovation Solution
A method that uses density-based representations of 3D models to identify and remove non-manufacturable corners and cave-ins by adjusting milling depths, ensuring tool accessibility and maintaining the overall volume of the model, thereby facilitating 2.5-axis machining without requiring boundary surface information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If CAD software generates 3D models using topology optimization for subtractive manufacturing, then design objectives such as minimizing weight are improved, but non-manufacturable corners and cave-ins are created that cannot be processed by 2.5-axis machining
Solution Approach 1:
The system performs preliminary analysis of the generatively designed 3D model to identify non-manufacturable corners and cave-ins before actual manufacturing. By detecting these features in advance and modifying the model accordingly, the system prevents manufacturing failures while preserving the weight optimization benefits of generative design.
Solution Approach 2:
The system transitions from working with boundary surface representations (B-Rep) to volumetric representations using density-based models. This dimensional shift allows the system to analyze and modify internal geometry features that affect manufacturability, such as adjusting material distribution in problematic corner and cave-in regions without altering the external boundaries.
2Ease of manufacture
If boundary surface information is used to identify and remove non-manufacturable features, then manufacturability is improved, but the process becomes complex and time-consuming
Solution Approach 1:
The system replaces traditional mechanical/CAD-based boundary surface analysis with a computational field-based approach using density functions. Instead of manipulating complex surface geometries to identify manufacturability issues, the system uses density-based volumetric analysis that simplifies the detection and modification of non-manufacturable features through mathematical operations on density fields.
3Ease of manufacture
If non-manufacturable corners and cave-ins are removed from the 3D model, then manufacturability for 2.5-axis machining is improved, but model volume may be reduced
Solution Approach 1:
The system applies local modifications only to specific regions identified as non-manufacturable (corners and cave-ins) while preserving the rest of the generatively optimized geometry. By targeting only the problematic local areas and using density-based adjustments, the system maintains overall model volume and design objectives while ensuring manufacturability in the affected regions.
Data Source
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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 and data specifying a starting element for each of multiple different subsets of elements; processing starting elements having milling depths associated with layers below a top most layer, the processing including, for a current starting element for a current layer, identifying other starting elements that have milling depths associated with a layer above the current layer and are closer to the current starting element than an amount at least equal to a radius of a smallest available milling tool, calculating a maximum angular difference, and moving the milling depth for the element subset of the current starting element to a layer above the current layer, responsive to the maximum angular difference being greater than a threshold, to remove a non-manufacturable corner.