Self-supporting 3D Design via Angle Analysis
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Solution Overview
Problem
Additive manufacturing techniques often result in thermal and mechanical stresses that can deform objects or prevent the build process due to expansion and shrinkage of materials, necessitating the use of supports which increase manufacturing time and cost.
Innovation Solution
A computer-controlled system modifies the design file of 3D objects to make them self-supporting by adding edges and adjusting wall thickness, eliminating the need for additional supports by determining surface angles and generating additional surfaces along edges to ensure the object is self-supporting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If supports are added to prevent deformation during additive manufacturing, then the object's shape accuracy is improved, but the manufacturing time and material usage increase
Solution Approach 1:
The system performs preliminary analysis of the 3D model to identify surfaces requiring support, calculates optimal support placement locations, and generates support structure designs before manufacturing begins. This pre-planning enables automated support generation that minimizes manual intervention and reduces overall manufacturing time despite adding support structures.
Solution Approach 2:
The system makes the design file self-supporting by automatically modifying it to include necessary support structures without requiring external support apparatus or manual setup. The automated support generation embedded in the design file enables the object to support itself during manufacturing, eliminating the need for separate support placement operations.
2Manufacturing precision
If supports are added to prevent deformation during additive manufacturing, then the object's shape accuracy is improved, but the material usage increases
Solution Approach 1:
The system applies support structures selectively only to specific surfaces and regions of the 3D model that require support based on angle analysis and stability calculations. Rather than adding universal support throughout the entire build, the system concentrates material only where geometrically necessary, minimizing overall material consumption while maintaining shape accuracy in critical areas.
Solution Approach 2:
The system modifies parameters of the design file including surface angles, wall thicknesses, and geometric features to create self-supporting structures. By changing these design parameters, the object becomes inherently stable during manufacturing without requiring excessive external support material, thus reducing total material usage while maintaining manufacturing precision.
3Manufacturing precision
If supports are added to prevent deformation during additive manufacturing, then the object's shape accuracy is improved, but the post-processing work increases
Solution Approach 1:
The system extracts and removes support structures from the final object after manufacturing is complete. By designing supports that are clearly distinguishable from the main object geometry and positioned in accessible locations, the system facilitates efficient automated or manual support removal, reducing the complexity and time required for post-processing operations.
Solution Approach 2:
The support structures serve as temporary intermediary elements that facilitate the manufacturing process but are not part of the final product. The system designs these intermediary supports to be easily separable from the main object, allowing them to be removed without damaging the final geometry or requiring complex post-processing operations.
4Stability of the object's composition
If wall thickness is increased to ensure self-supporting capability, then the object's structural stability is improved, but the material usage increases
Solution Approach 1:
The system applies increased wall thickness selectively only to specific portions of the object where structural stability is critical for self-supporting capability. Rather than uniformly thickening the entire object, the system concentrates additional material only in regions where geometric stability is needed, minimizing overall material usage while maintaining structural integrity in critical areas.
Solution Approach 2:
The system modifies wall thickness parameters locally based on stability requirements calculated from the object's geometry and manufacturing orientation. By dynamically adjusting thickness parameters in different regions rather than applying a uniform increase, the system achieves necessary structural stability with minimal additional material consumption.
Data Source
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AI summary
A system and method for modifying features in designs of objects to make them physically capable of being manufactured using additive manufacturing techniques and machines is provided, carrying out the following steps: Determine if one or more surfaces of the object have a surface angle below a threshold angle; designate one or more edges including a first edge, the first edge being between a first surface of the one or more surfaces and a second surface of the one or more surfaces, wherein the first surface has a surface angle below the threshold angle and the second surface has a surface angle equal to or above the threshold angle; and generate one or more additional surfaces along the one or more edges in the design file.