Topology Optimization Geometry Smoothing Engine
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Solution Overview
Problem
Topology optimization processes often produce coarse, rigid, or non-smooth geometries due to design space discretization requirements for finite element analyses, which can result in inefficient and unrefined 3D printed parts.
Innovation Solution
The described system includes a geometry processing engine that smoothes, conforms, and converts topology optimized geometries into CAD-editable models, enhancing resolution and preserving original geometry characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If topology optimization is performed with fine discretization granularity to improve geometry smoothness, then manufacturing precision and aesthetics improve, but computational resources and processing time increase significantly
Solution Approach 1:
The patent segments the topology optimization process into two distinct stages: a coarse optimization phase that determines the overall material distribution, and a fine refinement phase that smooths the geometry. This segmentation allows the computationally expensive fine discretization to be applied only to specific regions or iterations, rather than the entire design space, thereby reducing total computational resources while maintaining geometry smoothness.
Solution Approach 2:
The patent applies preliminary smoothing operations and geometry corrections after the initial coarse topology optimization but before final fine discretization. This preliminary action prepares the geometry in advance, reducing the complexity of subsequent fine discretization operations and lowering the overall computational burden while still achieving the desired smoothness.
2Productivity
If topology optimization uses coarse discretization to reduce computational resources, then processing time decreases, but the resulting geometries become rigid and non-smooth
Solution Approach 1:
The patent dynamically changes the discretization parameter granularity during the optimization process. It starts with coarse discretization for rapid initial optimization, then progressively refines the discretization in specific regions or for specific iterations. This parameter change strategy maintains processing efficiency while progressively improving geometry smoothness without requiring consistently fine discretization throughout.
Solution Approach 2:
The patent applies fine discretization and smoothing operations locally to specific regions of the geometry rather than uniformly across the entire design space. By identifying regions that require higher precision (such as areas with complex curvature or stress concentrations) and applying fine discretization only there, the system achieves improved geometry smoothness where needed while maintaining coarse discretization in other areas, thus preserving processing efficiency.
3Weight of moving object
If topology optimization produces optimized material layouts, then weight reduction and performance improvement are achieved, but the geometries require additional processing to be suitable for 3D printing
Solution Approach 1:
The patent introduces an intermediary geometry processing stage that acts as a mediator between the topology optimization output and the 3D printing input requirements. This intermediary stage includes operations such as mesh smoothing, hole filling, surface repair, and support structure generation. These intermediary processing steps transform the optimized but raw geometry into a manufacturing-ready format without altering the weight-optimizing material layout achieved by topology optimization.
Solution Approach 2:
The patent performs preliminary geometry processing and repair operations immediately after topology optimization but before 3D printing preparation. This preliminary action includes generating initial support structures, repairing mesh defects, and smoothing surfaces in advance. By performing these actions preliminarily, the system ensures that the weight-optimized geometry is properly prepared for 3D printing without requiring extensive post-processing, thus improving ease of manufacture while preserving the weight reduction benefits.
Data Source
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AI summary
A computing system may include a geometry access engine configured to access geometries associated with a topology optimization process, including an original geometry that represents a design space upon which the topology optimization process applies to as well as a topology optimized geometry that represents an output of the topology optimization process performed for the original geometry. The system may also include geometry processing engine configured to generate a final geometry from the topology optimized geometry, including by conforming the topology optimized geometry to the original geometry at portions of the topology optimized geometry that correspond to fixed regions of the original geometry as well as smoothing the topology optimized geometry at portions that correspond to non-fixed regions of the original geometry.