Macrostructure topology generation with disparate physical simulation for Computer Aided Design and Manufacturing

Patent metadata

Field	Value
Publication number	US-11947334-B2
Application number	US-202117238116-A
Country	US
Kind code	B2
Filing date	Apr 22, 2021
Priority date	Nov 9, 2018
Publication date	Apr 2, 2024
Grant date	Apr 2, 2024

Abstract

Methods, systems, and apparatus, including medium-encoded computer program products, for computer aided design of physical structures using generative design processes, where three dimensional (3D) models of the physical structures can be produced to include lattices, hollows, holes, and combinations thereof, include: obtaining design criteria for an object; iteratively modifying 3D topology and shape(s) for the object using generative design process(es) that employ a macrostructure representation, e.g., using level-set method(s), in combination with physical simulation(s) that place void(s) in solid region(s) or solid(s) in void region(s) of the generative model of the object; and providing a 3D model of the generative design for the object for use in manufacturing a physical structure corresponding to the object using one or more computer-controlled manufacturing systems. The providing can include generating instructions for manufacturing machine(s), which can employ various manufacturing systems and techniques, including additive, subtractive and casting manufacturing methods.

First claim

What is claimed is:

1. A method comprising:
obtaining, by a computer aided design program, a design space for an object to be manufactured, a setup for physical simulation of the object, at least one design objective for the object, and at least one design constraint for the object;
iteratively modifying, by the computer aided design program, both a three dimensional topology of a generative model for the object and one or more outer shapes of the three dimensional topology using a generative design process that employs a level-set method of topology optimization and a level-set representation of the generative model in the design space, wherein the modifying comprises
changing a constitutive model for the physical simulation in accordance with a current iteration of the level-set representation and a homogenized lattice material representation that expresses stiffness of a lattice, which is composed of beams and void regions, as a function of lattice topology and volume fraction for the lattice with a uniform thickness of the beams in the lattice,
performing the physical simulation of the object using the changed constitutive model to produce a physical assessment with respect to the at least one design objective and the at least one design constraint,
computing shape change velocities for the level-set representation in the current iteration in accordance with the physical assessment, and
updating the level-set representation for the object using the shape change velocities with the level-set method;

adjusting, by the computer aided design program after the modifying completes changes to both the three dimensional topology and the one or more outer shapes of the three dimensional topology, (i) a thickness of the beams in the lattice, or (ii) a density of the lattice, in accordance with the physical simulation, the at least one design objective and the at least one design constraint, while keeping the three dimensional topology constant; and
providing, by the computer aided design program, a three dimensional model of the object in accordance with the three dimensional topology, the one or more outer shapes of the three dimensional topology and the adjusted lattice, for use in manufacturing a physical structure corresponding to the object using one or more computer-controlled manufacturing systems.

2. The method of claim 1 , wherein the modifying comprises adjusting the volume fraction for the homogenized lattice material representation in accordance with a constitutive matrix for the homogenized lattice material representation of lattice topology.

3. The method of claim 1 , wherein performing the physical simulation comprises performing finite element analysis simulation using a body-fitted mesh based solver, and the constitutive model is changed by mapping geometric field data and finite element simulation data between voxel grid points of the level-set representation of the generative model and elements of a solid mesh model used by the finite element analysis simulation.

4. The method of claim 1 , wherein changing the constitutive model for the physical simulation comprises (i) using void simulation elements outside the one or more outer shapes of the three dimensional topology and (ii) using the homogenized lattice material representation for simulation elements inside the one or more outer shapes of the three dimensional topology, in accordance with the current iteration of the level-set representation.

5. The method of claim 1 , wherein the obtaining comprises receiving input indicating an initial three dimensional model defining at least a portion of the design space.

6. The method of claim 5 , wherein the initial three dimensional model defines a boundary of the design space, changing the constitutive model for the physical simulation comprises (i) using the homogenized lattice material representation for simulation elements outside the one or more outer shapes of the three dimensional topology, but inside the boundary of the design space, and (ii) using solid simulation elements inside the one or more outer shapes of the three dimensional topology, in accordance with the current iteration of the level-set representation.

7. The method of claim 1 , wherein computing the shape change velocities comprises using an augmented Lagrangian method to compute advection velocities.

8. The method of claim 1 , wherein the homogenized lattice material representation expresses structural behavior of a given lattice as an anisotropic solid material being a continuous material with properties approximately equivalent to the given lattice.

9. The method of claim 1 , wherein the one or more computer-controlled manufacturing systems comprise an additive manufacturing machine, and the providing comprises:
generating toolpath specifications for the additive manufacturing machine from the three dimensional model; and
manufacturing the physical structure corresponding to the object with the additive manufacturing machine using the toolpath specifications.

10. A method comprising:
obtaining, by a computer aided design program, a design space for an object to be manufactured, a setup for physical simulation of the object, at least one design objective for the object, and at least one design constraint for the object;
iteratively modifying, by the computer aided design program, both a three dimensional topology of a generative model for the object and one or more outer shapes of the three dimensional topology using a generative design process that represents the three dimensional topology of the generative model as one or more boundaries between one or more solid regions and one or more void regions within the design space, wherein the modifying comprises
changing a constitutive model for the physical simulation in accordance with a current iteration of the three dimensional topology and the one or more outer shapes of the three dimensional topology being offset inward to define a hollow structure in the three dimensional topology,
performing the physical simulation of the object using the changed constitutive model to produce a physical assessment with respect to the at least one design objective and the at least one design constraint,
computing shape change velocities for the one or more outer shapes of the three dimensional topology in the current iteration in accordance with the physical assessment, and
updating the generative model for the object with the generative design process using the shape change velocities;

adjusting, by the computer aided design program after the modifying completes changes to both the three dimensional topology and the one or more outer shapes of the three dimensional topology, a thickness of the hollow structure in accordance with the physical simulation, the at least one design objective and the at least one design constraint, while keeping the one or more outer shapes of the three dimensional topology constant; and
providing, by the computer aided design program, a three dimensional model of the object in accordance with the three dimensional topology, the one or more outer shapes of the three dimensional topology and the adjusted thickness of the hollow structure, for use in manufacturing a physical structure corresponding to the object using one or more computer-controlled manufacturing systems.

11. The method of claim 10 , wherein the offset inward to define the hollow structure is a constant offset selected by a user of the computer aided design program.

12. The method of claim 10 , wherein performing the physical simulation comprises performing finite element analysis simulation using a body-fitted mesh based solver, and the constitutive model i

Assignees

• Autodesk Inc

Inventors

• Bandara Konara Mudiyanselage Kosala
• Willis Karl Darcy Daniel
• Harris Andrew John
• Banadyha Andriy
• Grandi Daniele
• Butscher Adrian Adam Thomas
• Bastian Andreas Linas
• Shayani Hooman

Classifications

• G05B19/4099 Primary

  Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• G05B19/182

  characterised by the machine tool function, e.g. thread cutting, cam making, tool direction control (G05B19/21 - G05B19/40 take precedence) · CPC title