3D Model Support Structure Generation via Virtual Ray Analysis
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Solution Overview
Problem
In additive manufacturing systems, unsupported layers in 3D models can shift or deform due to the partially pliable state of the material, necessitating the use of support structures to maintain the desired shape during the manufacturing process.
Innovation Solution
A method for generating and managing support structures in 3D models using a computing system that analyzes the model's geometry to determine areas requiring support, generates virtual rays to identify intersection points, and calculates the need for support structures based on angle thresholds, allowing for user interaction to modify and optimize the support structure configuration before manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If support structures are added to the 3D model to prevent layer shifting and deformation, then the stability and shape accuracy of the manufactured part is improved, but the complexity of the model increases and additional material is required
Solution Approach 1:
The system performs preliminary analysis of the 3D model geometry before manufacturing to automatically identify overhanging sections and calculate required support structures. This preliminary action determines optimal support placement and configuration, ensuring shape accuracy is maintained while avoiding unnecessary complexity from manual support design.
2Manufacturing precision
If support structures are added to the 3D model to prevent layer shifting and deformation, then the stability and shape accuracy of the manufactured part is improved, but the amount of material required increases
Solution Approach 1:
The system applies support structures only locally to specific overhanging sections identified through geometric analysis, rather than adding universal support throughout the entire model. The support configuration is optimized for each local region, providing necessary stability while minimizing overall material consumption.
3Stability of the object's composition
If support structures are added to the 3D model to prevent layer shifting and deformation, then the stability during manufacturing is improved, but the post-processing time and effort increases due to removal of supports
Solution Approach 1:
The system designs support structures that can be easily discarded after manufacturing while ensuring the primary model is recovered intact. The automated support generation creates optimized support configurations that minimize post-processing effort, allowing for efficient removal of supports and recovery of the final part with reduced time and effort.
Data Source
AI summary
Systems and methods for generating data for a support structure to be built with a digital manufacturing system. Virtual rays are generated that extend toward a digital representation of a three-dimensional model. Intersection points of the virtual rays and the outer surface of the three-dimensional model are determined. Support structures extending from the outer surface of the three-dimensional model at the intersection point are generated. Support structure requirements can be used to determine if a support structure should be generated. A user can alter the support structures prior to the building of the three-dimensional model.