3D Mesh Partitioning by Build Direction for Multi-Axis Printing

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Solution Overview

Problem

Existing additive manufacturing techniques are laborious and inefficient, particularly for objects with nonplanar interfaces, as they require laborious human intervention and are unsuitable for deconstructing complex geometries, often necessitating separate component manufacture and stitching, which is cumbersome and resource-intensive.

Innovation Solution

A system and method for build direction-based segmentation of 3D surface meshes, using a CAD or CAE system to partition the mesh into buildable and non-buildable segments based on initial and subsequent build directions, allowing for automatic or semi-automatic determination of buildable volumes and correlated build directions for multi-axis 3D printing, reducing the need for human intervention and resource consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If existing additive manufacturing techniques are used for objects with nonplanar interfaces, then the construction can be performed, but the process becomes laborious and inefficient requiring human intervention and separate component stitching

Engineering Contradiction:

Improveconstruction speedVSAvoidautomation level

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The patent applies segmentation by dividing the 3D object into multiple buildable segments based on build direction analysis. Each segment is independently processable by the additive manufacturing system, eliminating the need for manual stitching of separate components. The segmentation is performed automatically through algorithmic analysis of the object's geometry and build direction constraints.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs self-service through automated build direction determination and segment generation. The computer system automatically analyzes the 3D object, determines optimal build directions, generates buildable segments, and prepares construction data without requiring human intervention. This automation directly addresses the productivity-automation contradiction by making the system self-sufficient.

Inventive Principle:

Principle #25Self-service

2Device complexity

If existing techniques are used for complex geometries, then construction is possible, but separate component manufacture and stitching is necessary which is cumbersome and resource-intensive

Engineering Contradiction:

Improvegeometry complexityVSAvoidmanufacturing simplicity

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent segments complex geometries into buildable portions that can be constructed in a single additive manufacturing process. The segmentation algorithm automatically identifies suitable build directions and divides the object into segments that maintain geometric complexity while being manufacturable without separate component assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces build direction as an additional dimension for analyzing and manufacturing complex geometries. By determining optimal build directions and segments based on spatial orientation, the system simplifies the manufacturing process for complex shapes without requiring separate component fabrication and assembly.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Manufacturing precision

If manual segmentation and component stitching is performed, then construction accuracy can be maintained, but resource consumption increases and efficiency decreases

Engineering Contradiction:

Improveconstruction accuracyVSAvoidresource consumption

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The system performs self-service through automated segmentation and build preparation, eliminating the need for manual intervention while maintaining construction accuracy. The computer system automatically generates precise buildable segments and construction data, reducing both resource consumption and human labor requirements without sacrificing manufacturing precision.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical segmentation and stitching processes with automated computational methods. The computer system uses algorithms to perform build direction analysis, segment generation, and construction data preparation, substituting human labor and manual operations with automated digital processes that maintain precision while reducing resource consumption.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11599089B2Build direction-based partitioning for construction of a physical object through additive manufacturing

Publication Date: 2023.03.07 SIEMENS INDUSTRY SOFTWARE INC

AI summary

Systems and methods may support build direction-based partitioning for construction of a physical object through additive manufacturing. In some implementations, a system may access a surface mesh representative of a 3D object and an initial build direction for construction of the object using additive manufacturing. The system may partition the surface mesh into an initial buildable segment and a non-buildable segment based on the initial build direction. The system may iteratively determine subsequent build directions and partition off subsequent buildable segments from the unbuildable segment until no portion of the non-buildable segment remains. The determined buildable segments and correlated build directions may be provided to a multi-axis 3D printer for construction of the represented 3D object through additive manufacturing.