3D Part Request Interpretation for Automated Print Setup
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Solution Overview
Problem
Traditional manufacturing methods, such as injection molding and additive manufacturing, face high overhead costs due to the need for durable template components and skilled labor to configure manufacturing settings, which can be time-consuming and costly, especially when creating multiple copies of a part or applying two-dimensional images to three-dimensional parts.
Innovation Solution
A server-based system that interprets user design requests, selects 3D model files from a library, and automates the configuration of printer settings, allowing designers to efficiently create new model files by referencing similar models, thereby reducing the time and cost associated with part design and production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fabrication methods use reusable template components to shape many identical copies of a part, then manufacturing efficiency and consistency are improved, but the overhead cost increases due to the expensive manufacture of durable template components
Solution Approach 1:
The patent replaces expensive, durable template components (molds) with disposable additive manufacturing templates that are generated digitally and printed on-demand. These digital templates can be modified or discarded without physical retooling costs, eliminating the need for expensive reusable molds while maintaining manufacturing efficiency through automated generation and printing processes.
2Ease of manufacture
If additive manufacturing methods are used to form parts without template components, then overhead costs are reduced, but skilled labor is required to configure manufacturing settings which adds to overhead costs
Solution Approach 1:
The system enables automated self-configuration of additive manufacturing settings by using machine learning models that automatically determine optimal print orientations, support structures, and manufacturing parameters based on the part geometry and desired properties. This eliminates the need for skilled manual configuration while maintaining high-quality output, allowing the system to configure itself without human intervention.
Solution Approach 2:
The patent employs automated parameter optimization where manufacturing settings (orientation angles, layer thickness, support density) are dynamically adjusted based on part characteristics and manufacturing objectives. The system automatically modifies these parameters to achieve optimal results without requiring manual intervention from skilled operators.
3Manufacturing precision
If a designer creates a new 3D model file from scratch based on user description, then design accuracy is improved, but the time required increases substantially
Solution Approach 1:
The system performs preliminary design work by automatically generating initial 3D model proposals from user descriptions using natural language processing and generative design algorithms. These pre-generated models serve as starting points that designers can quickly review and refine, rather than creating models from scratch, significantly reducing design time while maintaining accuracy through iterative refinement.
Solution Approach 2:
The system uses generative design to create multiple candidate model variations that replicate or adapt existing design patterns and geometries based on user requirements. These generated models can be copied, modified, or combined to produce final designs, reducing the time needed for original design work while maintaining high accuracy through algorithmic optimization.
Data Source
AI summary
A factory server receives part requests from customer devices and controls one or more manufacturing tools, such as 3D printers, to fabricate the requested parts. The factory server implements several features to streamline the process of fabricating parts using the manufacturing tools. For instance, the factory server can facilitate the design of a part by extracting features from the part request and identifying model files having those features. The factory server can also select an orientation in which to fabricate the part and determine print settings to use when fabricating the part. In addition, the factory server can implement a process to fabricate a three-dimensional part with a two-dimensional image applied to one or more of its external surfaces. Furthermore, the factory server can also generate a layout of multiple part instances on a build plate of a 3D printer so that multiple part instances can be fabricated at once.