3D Printing Hollowing via Voxel Erosion and Vector Reconstruction
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Solution Overview
Problem
Conventional methods for hollowing out three-dimensional CAD models to create internal voids or microstructures are inefficient and prone to errors, especially for complex geometries, leading to undesirable sharp edges and non-trivial intersection issues during the shelling process.
Innovation Solution
The method involves converting a vector-based CAD model to a digitized voxel representation, eroding it to create an internal volume, and then generating a vector-based surface representation of the internal space, which can be combined with the original model to form a hollowed-out model suitable for three-dimensional printing, allowing for the introduction of microstructures without surface intersections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the conventional shelling approach moves outer surfaces inwards by a fixed amount, then the internal volume is created, but surface intersections and geometric errors occur especially for complex objects
Solution Approach 1:
The patent introduces a digitised voxel representation as an intermediary between the vector-based CAD model and the final hollowed model. This intermediary voxel model serves as a mediator that simplifies the shelling operation, avoiding direct manipulation of complex vector surfaces and eliminating intersection problems while maintaining manufacturing precision.
Solution Approach 2:
The patent replaces the mechanical geometric operation of moving vector surfaces (which causes intersections) with a digital voxel-based erosion process. This substitution transforms a problematic geometric manipulation into a straightforward digital operation that is inherently more robust and easier to control.
2Ease of manufacture
If microstructure is merged with internal surfaces using conventional techniques, then internal framework is created, but sharp edges and non-trivial intersections occur
Solution Approach 1:
The voxel model serves as an intermediary that facilitates easy merging of microstructures. By representing both the object and microstructure in voxel space, the patent enables straightforward Boolean operations without the geometric complexity that causes sharp edges and intersections in traditional vector-based approaches.
Solution Approach 2:
The patent changes the representation parameter from vector-based geometry to voxel-based digital representation. This parameter change fundamentally alters how microstructures are integrated, transforming a complex geometric merging problem into a simple digital operation that maintains edge quality while improving ease of manufacture.
3Manufacturing precision
If manual handling is used for surface intersections in simple objects, then some corrections are possible, but the process becomes inconvenient and inefficient
Solution Approach 1:
The voxel-based erosion process is self-correcting and does not require manual intervention. The digital nature of voxel operations automatically handles all geometric relationships, eliminating the need for manual surface correction while maintaining high precision and improving processing efficiency simultaneously.
4Quantity of substance
If solid interior is replaced with void or framework, then material usage is reduced, but the shelling process becomes more complex
Solution Approach 1:
The patent replaces the complex mechanical shelling process with a simple digital voxel erosion operation. This substitution dramatically reduces process complexity while enabling the creation of hollowed models and microstructures, thereby reducing material consumption without increasing process complexity.
Data Source
AI summary
A method for preparing image data for three-dimensional printing in which a digitized (e.g. voxelized) representation of a virtual three-dimensional object (e.g. CAD model) is eroded to create an internal volume for the object. Subsequently, a vector-based surface representation of this internal volume is generated and simply combined with a corresponding vector-based surface representation of the original virtual three-dimensional object to yield a hollowed out model in a format suitable for three-dimensional printing.A microstructure may be introduced into the interior of the hollowed out model, e.g. by extracting a volume corresponding to the inverse of that microstructure from the eroded digitized representation.