Generative 3D Shape Layering for 2.5-Axis CNC Milling
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Solution Overview
Problem
Current CAD software limitations in generating designs for 2.5-axis subtractive manufacturing processes, which require efficient manufacturing methods that can handle multiple milling directions without repositioning the workpiece, are not adequately addressed by existing generative design solvers that often rely on discrete and approximate surfaces, making it difficult to optimize designs for conventional machining tools.
Innovation Solution
A method that iteratively modifies density-based representations of 3D shapes in accordance with milling directions of 2.5-axis subtractive manufacturing processes, adjusting density values and layering to produce toolpath specifications compatible with 2.5-axis machining, allowing for the use of multi-axis CNC machines without repositioning the workpiece, and optimizing designs for efficient manufacturing by performing numerical simulations and sensitivity analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If generative design solvers use discrete and approximate surfaces for 3D geometry generation, then the design space exploration and manufacturing flexibility are improved, but the manufacturing precision and surface quality deteriorate
Solution Approach 1:
The patent segments the continuous design space into discrete volumetric elements (voxels or tetrahedral meshes), allowing independent manipulation of each element's density or presence. This segmentation enables the solver to explore manufacturing flexibility through discrete adjustments while maintaining surface quality by controlling the density distribution across segmented elements.
Solution Approach 2:
The patent changes the representation parameter from continuous surface geometry to discrete density values assigned to volumetric elements. By adjusting density parameters of individual elements rather than modifying continuous surfaces, the system achieves both manufacturing flexibility through parameter variation and surface quality through controlled density transitions.
2Manufacturing precision
If complex multi-axis CNC machining is used to achieve precise 3D geometries, then the manufacturing precision is improved, but the device complexity and manufacturing time increase
Solution Approach 1:
The patent performs preliminary action by pre-defining the density distribution of volumetric elements during the generative design phase, effectively pre-determining the final geometry. This preliminary specification of material distribution allows subsequent manufacturing to follow a predetermined path, reducing the need for complex real-time multi-axis machining decisions and simplifying the manufacturing system requirements.
3Manufacturing precision
If traditional B-Rep format is used for storing 3D geometry, then the mathematical precision and surface smoothness are improved, but the compatibility with generative design solvers and manufacturing processes deteriorates
Solution Approach 1:
The patent transitions from traditional 2D surface-based B-Rep representation to a 3D volumetric representation using voxels or tetrahedral meshes. This dimensional shift from surface to volume enables direct compatibility with generative design solvers that operate on volumetric data, while maintaining manufacturing precision through controlled density assignment to volumetric elements.
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, design criteria, and in-use case(s); iteratively modifying a generatively designed shape in the design space in accordance with the design criteria and the in-use case(s) using a density-based representation of the generatively designed shape and including adjusting the density-based representation of the generatively designed three dimensional shape in accordance with a milling direction of a 2.5-axis subtractive manufacturing process in at least two iterations of the iteratively modifying; and providing the generatively designed shape for use in manufacturing a physical structure using computer-controlled manufacturing that employs the 2.5-axis subtractive manufacturing process.