Solid Identification Grid Engine for Additive Manufacturing Support Volume
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Solution Overview
Problem
Current additive manufacturing processes face challenges in quickly and accurately calculating the volume of support material needed for 3D parts, which complicates the pricing and planning of 3D printing operations.
Innovation Solution
The Solid Identification Grid (SIG) engine uses a tree data structure and collision detection techniques to calculate the support material volume by generating a grid of cells and pinging them until a subset of the tree data structure is reached, allowing for the determination of the total filled volume and subsequent support material volume, enabling efficient price quoting and process optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods are used to calculate support material volume, then calculation accuracy can be maintained, but processing time is excessive and prevents instant pricing
Solution Approach 1:
The patent segments the 3D digital model into a grid of discrete cells organized in cell arrays. Each cell can be independently evaluated to determine if it contains part of the digital model or requires support material. This segmentation enables parallel processing and rapid volume calculation by simply counting filled cells rather than performing complex geometric computations on the entire model.
Solution Approach 2:
The patent creates a simplified digital copy of the 3D model represented as a tree data structure that can be efficiently queried. Instead of working with the complex original mesh geometry, the system uses this copied hierarchical representation to quickly determine which grid cells intersect with the model, enabling instant support material volume calculation.
2Measurement precision
If detailed support material volume calculation is performed, then pricing accuracy is improved, but computational complexity increases
Solution Approach 1:
The patent replaces complex geometric computation mechanisms with a simpler grid-based counting mechanism. Instead of performing sophisticated mathematical operations to calculate volumes from 3D mesh data, the system uses a straightforward grid overlay approach where support material volume is determined by counting the number of grid cells that require support, providing accurate measurements with minimal computational complexity.
3Adaptability or versatility
If support material volume is calculated for all orientations, then optimal orientation selection is improved, but processing time increases
Solution Approach 1:
The patent performs preliminary calculation of support material volume for multiple standard orientations (e.g., aligning model axes with global X, Y, Z axes) before the actual printing process. This preliminary analysis allows the system to identify the optimal orientation that minimizes support material requirements, enabling adaptability in orientation selection without significant processing overhead during production.
Data Source
AI summary
A method for calculating a support material volume, the method comprising generating a grid of cells for a tree data structure of a digital part, where the cells define a plurality of cell arrays, and pinging the cells of one of the cell arrays until a cell containing a subset of the tree data structure is reached or until each cell in the cell array is pinged, where if a cell containing the subset of the tree data structure is reached, then designating the reached cell and all remaining unpinged cells in the cell array as filled. The method also includes repeating the pinging step for each remaining cell array to determine a total filled volume, and subtracting a volume of the digital part from the total filled volume to determine a support material volume.