3D Design File Compression via Unit Cell Definition
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Solution Overview
Problem
Large 3D design files, such as .stl files, are cumbersome due to their size, leading to storage and transfer issues and prolonged processing times for slicer applications, especially when representing detailed geometries or large volumes in 3D printing technologies.
Innovation Solution
The method involves defining a 'unit cell' that includes a single instance of a 3D article and its nearest neighbors, allowing the slicer application to generate instructions for printing multiple instances of this unit cell across the build plate, significantly reducing file size and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If detailed geometries and large volumes are represented in 3D design files, then manufacturing precision is improved, but file size increases leading to storage and transfer issues
Solution Approach 1:
The patent segments the 3D design file into a compact representation system that divides the model into manageable components. Instead of storing complete high-resolution geometry data for entire large-volume models, the system segments the representation into hierarchical levels of detail, where only essential structural information is stored at full resolution while other areas use simplified representations, thereby reducing overall file size while preserving manufacturing precision where needed
Solution Approach 2:
The patent introduces a new dimensional approach by adding metadata layers and hierarchical organization to the traditional 3D model representation. This includes storing geometry data in compressed formats with associated bounding box information, layer definitions, and feature hierarchies that allow the slicer to efficiently process only relevant portions of the model at each printing layer, effectively adding an organizational dimension that reduces data redundancy
2Manufacturing precision
If detailed geometries are represented in 3D design files, then manufacturing precision is improved, but processing time for slicer applications increases
Solution Approach 1:
The patent applies preliminary action by pre-processing the 3D model data during the file creation or import phase to organize geometry information into optimized structures. This includes pre-calculating bounding boxes, defining layer boundaries, and creating hierarchical feature relationships before the slicing operation begins, allowing the slicer to quickly navigate and process the model without performing intensive computations during the actual slicing process
Solution Approach 2:
The patent utilizes parameter changes by implementing variable resolution levels and adaptive data structures that adjust the amount of geometric detail stored based on the specific requirements of different model regions. Critical features maintain high precision while non-critical areas use coarser representations, and the system dynamically adjusts processing parameters based on the complexity of the current layer being sliced, reducing overall processing time while maintaining manufacturing precision
3Adaptability or versatility
If conventional 3D file formats are used, then compatibility with existing software is maintained, but storage requirements and processing time increase
Solution Approach 1:
The patent implements a hybrid approach where a compressed, optimized representation of the 3D model is created as a secondary data structure that references the original geometry. This copied representation includes simplified surface definitions, hierarchical feature trees, and pre-computed slicing information that can be processed independently, allowing the system to work with smaller data structures while maintaining compatibility with standard 3D printing workflows and software
Data Source
AI summary
A design with multiple instances of a three-dimensional article is printed by first defining a unit cell that includes a single instance of a three-dimensional article that repeats in the design along with its nearest neighbor elements in both a plane of a build plate of a target printer on which the design is to be printed and a plane orthogonal thereto. The design is represented in an output file of a design application and a slicer application then generates instructions to manufacture the design by the target printer. The instructions (g-code) include directions to print, for each of a specified number of layers a number of instances of the unit cell that can be accommodated within a build envelop of the target printer per layer as determined by said slicer application. The design is printed by the printer according to the instructions from the slicer application.