Generative 3D Models Filtered 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 result in inefficient manufacturing due to complex geometries that are difficult to produce, leading to increased CAM programming time, machining time, and the need for custom fixtures.
Innovation Solution
A computer-aided design method that iteratively modifies the geometry and topology of 3D models using generative design processes, incorporating geometry filtering and simulation results filtering to ensure manufacturability, producing models with flat top, bottom, and flank regions suitable for 2.5-axis milling, and dynamic tool sizing to facilitate efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex geometries are generated by current CAD software for subtractive manufacturing, then design creativity and structural optimization are improved, but manufacturing efficiency deteriorates due to increased CAM programming time and machining complexity
Solution Approach 1:
The patent applies preliminary action by integrating manufacturing constraints and geometry filtering directly into the generative design process before manufacturing begins. The system pre-filters generated geometries to ensure 2.5-axis manufacturability, eliminating the need for complex post-processing and CAM programming adjustments later in the workflow.
Solution Approach 2:
The patent changes parameters by modifying the generative design algorithm to incorporate specific manufacturing parameters for 2.5-axis milling. The system adjusts geometry generation parameters to produce flat top, bottom, and flank regions, transforming the design output to match manufacturing capabilities rather than fighting against them.
2Adaptability or versatility
If complex geometries with non-flat surfaces are produced, then design optimization is improved, but the need for custom fixtures increases, leading to increased device complexity and cost
Solution Approach 1:
The patent changes the geometric parameters of generated designs to include flat top, bottom, and flank regions. This parameter modification allows standard fixtures to be used instead of custom fixtures, reducing device complexity while maintaining design optimization capabilities.
3Strength
If generative design produces arbitrary 3D geometries, then structural performance is improved, but machining time increases due to complex toolpaths and multiple operations
Solution Approach 1:
The patent changes the geometric parameters of generatively designed parts to include flat surfaces suitable for 2.5-axis milling. This enables simpler toolpaths and more efficient machining operations while preserving the structural performance benefits of generative design.
Solution Approach 2:
The patent performs preliminary geometry filtering to ensure generated designs are compatible with efficient 2.5-axis machining processes. By pre-adapting geometries to suit the manufacturing process, the system eliminates time-consuming complex toolpath generation and multiple machining operations.
4Ease of manufacture
If detailed geometry filtering is applied to ensure 2.5-axis manufacturability, then ease of manufacture is improved, but design freedom is reduced
Solution Approach 1:
The patent changes the approach to geometry filtering by integrating manufacturing constraints directly into the generative design parameter space. Rather than filtering finished designs, the system generates geometries with built-in manufacturability parameters, maintaining design freedom within manufacturing boundaries.
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design of physical structures using generative design processes, where the 3D models of the physical structures are produced so as to facilitate manufacturing of the physical structures using 2.5-axis subtractive manufacturing systems and techniques, include: obtaining a design space for an object to be manufactured, design criteria, and load case(s); iteratively modifying a generatively designed 3D shape of the modeled object, including generating 2D profile representations (corresponding to discrete layers) of an updated version of the 3D shape, extruding the 2D profile representations along the milling direction, and forming a next version of the 3D shape of the modeled object from a combination of the 3D representations produced by the extruding; and providing the generatively designed 3D shape of the modeled object for use in manufacturing the physical structure using a 2.5-axis subtractive manufacturing process.