3D Print Support Mesh Generation for Accurate Low-Material Supports
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Solution Overview
Problem
Current rapid prototyping methods require labor-intensive manual verification and addition of support structures, leading to inadequate support in some regions of objects being produced, which increases production time and material costs.
Innovation Solution
A method for generating support structures using a computing device that defines support regions and points, transforms the support mesh into a support structure, and minimizes material cost by removing superfluous edges and transforming the mesh into columnar shapes, thereby automating the support design process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual verification and addition of support structures is used, then support accuracy can be improved, but production time and labor intensity increase
Solution Approach 1:
The system performs automatic support structure generation and verification without requiring manual intervention. The computing device automatically analyzes the 3D model, identifies support regions, generates support structures, and verifies their adequacy, making the system self-sufficient and eliminating labor-intensive manual operations.
Solution Approach 2:
The patent replaces manual mechanical operations with automated computational processes. Instead of manually verifying and adding support structures, the system uses algorithms to automatically generate and verify support structures, substituting human labor with computational automation.
2Adaptability or versatility
If manual support structure design is used, then flexibility in design can be maintained, but material costs and production time increase
Solution Approach 1:
The system automatically verifies the adequacy of generated support structures and performs iterative optimization without manual intervention. This self-verification and optimization process ensures material efficiency while maintaining design flexibility, as the system adapts the support structures automatically based on verification results.
Solution Approach 2:
The system implements a feedback loop where generated support structures are automatically verified for adequacy. Based on verification results, the system iteratively optimizes the support structures, ensuring minimal material usage while maintaining structural integrity and design requirements.
3Stability of the object's composition
If comprehensive support structures are added to prevent deformations, then object stability improves, but material consumption and production time increase
Solution Approach 1:
The system automatically verifies support structure adequacy and iteratively optimizes them to provide only the necessary support. This feedback-driven optimization ensures that support structures are sufficient to prevent deformations and ensure stability without excessive material consumption, as the system removes unnecessary support elements through iterative refinement.
Solution Approach 2:
The system iteratively optimizes support structure parameters such as thickness, density, and distribution to achieve minimal material consumption while maintaining object stability. By adjusting these parameters through automated verification and optimization, the system finds the optimal balance between stability and material efficiency.
4Stability of the object's composition
If support structures are made more robust to prevent deformations, then object stability improves, but ease of separation deteriorates
Solution Approach 1:
The system generates support structures with varying local properties - more robust in regions requiring stability and less intrusive in regions requiring easy separation. The automatic verification and optimization process identifies different regional requirements and adjusts support structure characteristics accordingly, providing localized quality variations.
Solution Approach 2:
The system optimizes support structure parameters such as thickness, density, and geometry to achieve the right balance between stability and ease of separation. By iteratively adjusting these parameters through automated verification, the system creates support structures that are sufficiently robust for stability but designed for easy removal afterward.
Data Source
AI summary
The present invention is directed to an improved method for supporting an object made by means of stereo lithography or any other rapid prototype production method. The generation of the support begins by determining the region that requires support in each layer of the object and defines a number of support points in this region. In a next step, a support mesh is generated connected to the object using these support points. The present invention also discloses different techniques that reduce superfluous edges to further optimize the support mesh. Finally, a support is generated from this support mesh. The present invention may facilitate the generation of supports data by employing more automation and less user analysis.