Lattice Solid Interface Particle Trap Elimination
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Solution Overview
Problem
Existing 3D modeling software for additive manufacturing struggles with creating robust lattice-solid interfaces, often resulting in faulty or disconnected pieces due to particle traps at the interface between lattice and solid regions, which can lead to issues like trapped powder during the manufacturing process, especially in critical applications like medical implants.
Innovation Solution
The software identifies potential particle traps by comparing junction distances to a threshold value and modifies the cell space by removing beams and moving junctions to the surface, generating a convex hull to eliminate traps and ensure overlap between lattice and solid regions, thereby enhancing the connection and preventing particle entrapment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lattice structures are used in additive manufacturing, then weight reduction and performance optimization are achieved, but particle traps form at the interface between lattice and solid regions causing faulty or disconnected pieces
Solution Approach 1:
The software performs preliminary detection and modification of the lattice structure before manufacturing. It identifies potential particle traps by comparing junction distances to threshold values and modifies cell space by removing beams and moving junctions to the surface, preventing particle entrapment before the additive manufacturing process begins
Solution Approach 2:
The patent introduces an intermediary software layer between design and manufacturing that acts as a mediator. This software analyzes the lattice design, detects potential particle traps, and automatically modifies the structure by adjusting junction positions and removing problematic beams, ensuring reliable interfaces without requiring manual intervention
2Adaptability or versatility
If complex lattice structures with random variation in beam thickness and junction placement are generated, then design flexibility and performance optimization improve, but particle trap detection and interface robustness become more difficult
Solution Approach 1:
The software performs self-service by automatically analyzing its own generated lattice structures. It calculates distances between junctions and surfaces, compares them to threshold values, and autonomously identifies potential particle traps without external intervention, then modifies the structure to eliminate detected issues
Solution Approach 2:
The patent replaces manual or mechanical inspection methods with an automated computational system. The software uses algorithmic distance calculations and threshold comparisons to detect particle traps, substituting physical measurement and manual analysis with automated digital detection that can handle complex random variations efficiently
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for designing three dimensional lattice structures include, in one aspect, a method including: obtaining a lattice within a 3D lattice design space for a 3D model being created with a 3D modeling program; identifying junctions in the lattice that are potential sources of particle traps at an interface between the 3D lattice design space and a surface present in the 3D model; and removing the potential sources of particle traps by modifying cell space defined between the identified junctions and the surface. In addition, the surface can be a surface of a solid region defined in the 3D model, and the method can include: identifying beams in the lattice having junctions lying on the surface; and extending each of the identified beams by a length amount to cause overlap between the identified beams and the solid region.