Additive fabrication support structures

Patent metadata

Field	Value
Publication number	US-11801646-B2
Application number	US-202117556069-A
Country	US
Kind code	B2
Filing date	Dec 20, 2021
Priority date	Apr 5, 2013
Publication date	Oct 31, 2023
Grant date	Oct 31, 2023

Abstract

Techniques for evaluating support for an object to be fabricated via an additive fabrication device are provided. In some embodiments, a three-dimensional representation of the object is obtained and a plurality of voxels corresponding to the representation of the object is generated. A first supportedness value may be assigned to a first voxel of the plurality of voxels based on an amount of support provided by a support structure to the first voxel, and a second supportedness value determined for a second voxel of the plurality of voxels, wherein the second voxel neighbors the first voxel, and wherein the second supportedness value is determined based on the first supportedness value of the first voxel and a weight value representing a transmission rate of supportedness through voxels of the plurality of voxels.

First claim

What is claimed is:

1. A computer-implemented method of generating a support structure for an object represented by a three-dimensional model, the support structure and the object to be fabricated via additive fabrication, the method comprising:
determining, using at least one processor, a direction normal to the surface of the object at each of one or more surface points of the object;
generating, using the at least one processor, a support structure for the object, the support structure comprising:
a scaffolding portion; and
one or more support tips coupled to the scaffolding portion, and coupled to the object at the one or more surface points, wherein the one or more support tips comprise triangular prisms and are thinner than at least part of the scaffolding portion, and wherein an orientation of each of the one or more support tips is determined based at least in part on the direction normal to the surface of the object determined for the surface point to which the support tip is coupled; and

providing instructions to an additive fabrication device that, when executed by the additive fabrication device, cause the additive fabrication device to fabricate the object and the support structure.

2. The method of claim 1 , wherein the one or more support tips each extend outward from ones of the one or more surface points to respective points of a first set of points, and wherein the scaffolding portion comprises vertical supports connected to one or more support tips at the first set of points.

3. The method of claim 2 , further comprising determining locations of the first set of points by determining an offset from the one or more surface points along a vector normal to the surface of the object at a respective surface point.

4. The method of claim 1 , wherein determining the direction normal to the surface of the object for at least a first surface point of the one or more surface points comprises:
constructing, using the at least one processor, a voxel representation of the object, the representation comprising a plurality of voxels;
identifying, using the at least one processor, a first voxel of the plurality of voxels as comprising the first surface point; and
calculating, using the at least one processor, the direction normal to the surface of the object for the first surface point by determining whether one or more voxels neighboring the first voxel are exterior to the object.

5. The method of claim 1 , wherein determining the direction normal to the surface of the object for at least a first surface point of the one or more surface points comprises:
accessing, using the at least one processor, data describing a plurality of triangles that describe the object, the data comprising a normal direction for each of the plurality of triangles;
identifying, using the at least one processor, a first triangle of the plurality of triangles as comprising the first surface point; and
identifying, using the at least one processor, the normal direction associated with the first triangle as the direction normal to the surface of the object for the first surface point.

6. The method of claim 1 , wherein some, but not all, of the one or more support tips are oriented in the direction normal to the surface of the object determined for the surface point to which the support tip is coupled.

7. The method of claim 1 , wherein the orientation of at least a portion of the one or more support tips is determined by applying an offset, based on directions of expected forces at the surface point to which the support tip is coupled, to the direction normal to the surface of the object determined for the surface point.

8. A computer-implemented method of generating a support structure for an object represented by a three-dimensional model, the support structure and the object to be fabricated via additive fabrication, the method comprising:
generating, using at least one processor, a support structure for the object, the support structure comprising:
a scaffolding portion; and
one or more support tips coupled to the scaffolding portion, and coupled to the object at one or more surface points, wherein the one or more support tips comprise triangular prisms and are thinner than at least part of the scaffolding portion, and wherein the one or more support tips are generated by the at least one processor with geometries that depend, at least in part, upon a degree of support to avoid mechanical damage calculated based on directions of expected forces at respective surface points; and

providing instructions to an additive fabrication device that, when executed by the additive fabrication device, cause the additive fabrication device to fabricate the object and the support structure.

9. The method of claim 8 , wherein the geometries include an asymmetric cross-sectional area of contact with the object.

10. The method of claim 8 , wherein at least a subset of the support tip geometries include a long axis, and wherein the tips of the subset are positioned on the object such that the long axis of each tip is substantially perpendicular to a line extending from a centroid of the object.

11. The method of claim 8 , wherein at least a subset of the support tip geometries include a long axis, and wherein the tips of the subset are positioned on the object such that the long axis of each tip is substantially normal to a direction of a force predicted by the at least one processor to be exerted on the object during fabrication thereof.

12. The method of claim 1 , further comprising determining, by the at least one processor, a plurality of layers that together correspond to a shape of the support structure.

13. The method of claim 1 , wherein a length of at least a first support tip of the one or more support tips is less than 10% of a length of the at least one scaffolding portion.

14. The method of claim 1 , wherein each of the one or more support tips contacts the scaffolding portion at a non-zero angle.

15. A computer-implemented method of generating a support structure for an object represented by a three-dimensional model, the support structure and the object to be fabricated via additive fabrication, the method comprising:
generating, using at least one processor, a support structure for the object, the support structure comprising:
a scaffolding portion, wherein the scaffolding portion is generated by the at least one processor based on a minimum spanning tree; and
one or more support tips coupled to the scaffolding portion, and coupled to the object at one or more surface points, wherein the one or more support tips comprise triangular prisms and are thinner than at least part of the scaffolding portion; and

providing instructions to an additive fabrication device that, when executed by the additive fabrication device, cause the additive fabrication device to fabricate the object and the support structure.

16. The method of claim 8 , wherein the one or more support tips each extend outward from ones of the one or more surface points to respective points of a first set of points, and wherein the scaffolding portion comprises vertical supports connected to one or more support tips at the first set of points.

17. The method of claim 16 , further comprising determining locations of the first set of points by determining an offset from the one or more surface points along a vector normal to the surface of the object at a respective surface point.

18. The method of claim 8 , further comprising determining, by the at least one processor, a plurality of layers that tog

Assignees

• Formlabs Inc

Inventors

• Wighton Shane
• Lobovsky Maxim
• Schmidt-Nielsen Peter

Classifications

• B29C64/40 Primary

  Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof · CPC title

• B29C33/3842

  Manufacturing moulds, e.g. shaping the mould surface by machining · CPC title

• B29C33/448

  destructible (B29C33/52 takes precedence; in particular used in injection moulding B29C45/4457) · CPC title

• B29C64/106

  using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material · CPC title

• B29C64/112

  using individual droplets, e.g. from jetting heads · CPC title