Voxelization for 3D Printing Eliminates Contour Data Artifacts
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Solution Overview
Problem
Existing three-dimensional rapid prototyping methods using linear solidification face delays and inaccuracies due to the generation of contour data, which can be flawed by mesh imperfections and varying energy density along the scanning axis, leading to geometrical artifacts in the finished objects.
Innovation Solution
The method employs voxelization to generate solidification energy source event data directly from three-dimensional object data, eliminating the need for contour data and compensating for variations in energy density by using a compensation function that relates solidification length to scanning axis position and time, ensuring accurate and efficient energy distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If contour data is generated by slicing three-dimensional object data to produce solidification energy source event data, then the process can be completed using conventional methods, but the processing time is prolonged and mesh imperfections cause geometrical artifacts in the finished object
Solution Approach 1:
The patent extracts and eliminates the problematic contour data generation step from the conventional slicing process. By directly processing three-dimensional object data into solidification energy source event data without creating contour data intermediates, the method removes the source of mesh imperfections and geometrical artifacts while reducing processing time.
Solution Approach 2:
The patent transitions from two-dimensional contour-based processing to three-dimensional voxel-based processing. By working directly with volumetric data and generating solidification events in three-dimensional space, the method avoids the dimensional reduction that causes mesh artifacts and enables more accurate representation of complex geometries.
2Manufacturing precision
If contour data is generated by slicing three-dimensional object data, then conventional solidification processes can be applied, but varying energy density along the scanning axis causes inaccuracies and geometrical artifacts
Solution Approach 1:
The patent applies local quality by generating position-specific solidification energy source event data that accounts for varying energy density at different locations along the scanning axis. Each solidification event is customized with parameters tailored to its specific position, ensuring uniform solidification quality throughout the object despite variations in energy distribution.
Solution Approach 2:
The patent changes the parameters of solidification energy source event data based on position along the scanning axis. By dynamically adjusting solidification parameters such as energy duration, intensity, or timing according to local conditions, the method compensates for energy density variations and eliminates geometrical artifacts.
3Adaptability or versatility
If STL data with mesh of polygons is used to define object shape, then the object can be represented in three-dimensional space, but mesh imperfections such as overlapping and flipped elements create invalid solidification sequences
Solution Approach 1:
The patent creates a voxel-based copy or representation of the mesh data that eliminates geometric imperfections. By converting polygonal mesh data into a volumetric voxel model, the method preserves the essential shape information while removing overlapping and flipped element errors that invalidate solidification sequences.
Solution Approach 2:
The patent applies beforehand cushioning by preprocessing the three-dimensional object data to identify and correct potential mesh imperfections before they can affect solidification. The voxelization process acts as a buffer that prevents invalid geometrical data from propagating into the solidification sequence generation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces processing time and enhances the accuracy of three-dimensional object formation by eliminating mesh imperfections and energy density variations, resulting in improved geometric fidelity and reduced inaccuracies in the manufactured objects.
Implementation Method 1
solidification energy source event data comprises string data in the form of a plurality of data strings, each of which includes a plurality of time values. The time values dictate times at which the solidification energy source is energized and de-energized.
Implementation Method 2
The linear solidification device also includes a scanning device that scans solidification energy received from the source of solidification energy onto the solidifiable material along the scanning axis.
Data Source
Figure 1A
Figure 1B
Figure 2A~2D
AI summary
An apparatus and method for making a three-dimensional object from a solidifiable material using a linear solidification device and contourless object data is shown and described. A voxel matrix is superimposed over an object model defined by three-dimensional object data to determine active voxels that intersect at least a portion of the object model. The active voxels are related to a path generation reference frame of an apparatus for making a three-dimensional object to generate solidification energy source event data that defines scanning (y) axis location and/or solidification times at which a linear solidification device supplies solidification energy to a solidifiable material.