Shape modification for self-supporting structures in additive manufacturing

Patent metadata

Field	Value
Publication number	US-12430852-B2
Application number	US-202218049577-A
Country	US
Kind code	B2
Filing date	Oct 25, 2022
Priority date	Oct 25, 2022
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

This disclosure teaches techniques, devices, and systems for automatically modifying a 3-Dimensional (3D) object model. The apparatus comprising a memory and a processing device coupled to the memory. The processor and the memory are configured to obtain an input 3D object model comprising an input 3D mesh, analyze the input 3D mesh to identify unprintable overhangs that have an angle over an overhang angle limit and identify vertices associated with the unprintable overhangs as active vertices, and perform an optimization process to move the active vertices to eliminate the unprintable overhangs and generate a modified 3D mesh. The optimization process includes a gradient descent search algorithm performed on an objective function comprising a cost function configured to minimize a difference between the input 3D mesh and the modified 3D mesh subject to an overhang constraint related to the overhang angle limit.

First claim

What is claimed is:

1. An apparatus for automatically modifying a 3-Dimensional (3D) object model, the apparatus comprising:
a memory;
a processing device coupled to the memory, wherein the processing device and the memory are configured to:
obtain an input 3D object model comprising an input 3D mesh;
analyze the input 3D mesh to identify unprintable overhangs that have an angle over an overhang angle limit and identify vertices associated with the unprintable overhangs as active vertices; and
perform an optimization process to move the active vertices of the input 3D mesh to eliminate the unprintable overhangs and generate an output 3D mesh, wherein the optimization process is divided into a series of suboptimizations that each generate a modified 3D mesh resulting, eventually, the output 3D mesh;
wherein at each suboptimization, the processing device is to:
perform a gradient descent search algorithm on an objective function, wherein the objective function comprises a cost function that represents a difference between the input 3D mesh and the modified 3D mesh, and wherein the gradient descent search algorithm is to minimize the objective function to minimize the difference between the input 3D mesh and the modified 3D mesh subject to an overhang constraint comprising an optimization angle related to the overhang angle limit, wherein the modified 3D mesh is determined by multiplying a gradient of the objective function by a step size;
perform a topology validation process to determine whether the modified 3D mesh is invalid due to an intersection of portions of the modified 3D mesh; and
responsive to determining that the modified 3D mesh is not invalid and that the optimization angle is over the overhang angle limit, reduce the optimization angle to be used for the overhang constraint in the next suboptimization by an increment based on the step size.

2. The apparatus of claim 1 , wherein the objective function further comprises a pseudo-energy regularization term configured to avoid mesh deformation.

3. The apparatus of claim 2 , wherein the pseudo-energy regularization term is based on sphere packing.

4. The apparatus of claim 1 , wherein the overhang constraint comprises a face overhang constraint that constrains an angle between a build direction and a normal vector of each face in the modified 3D mesh to be less than the overhang angle limit.

5. The apparatus of claim 1 , wherein the overhang constraint comprises an edge overhang constraint that constrains an angle between a build direction and each edge in the modified 3D mesh to be less than the overhang angle limit.

6. The apparatus of claim 1 , wherein the overhang constraint comprises a stalactite constraint imposed an any downward facing vertex of the modified 3D mesh to ensure that the downward facing vertex is not a local minimum among its neighboring vertices.

7. The apparatus of claim 1 , wherein the gradient descent search algorithm is further subject to an outward constraint that restricts movement of any vertex in the modified 3D mesh to be in an outward directed compared to a surface of the input 3D mesh.

8. The apparatus of claim 1 , wherein the overhang constraint is a weak form of a face overhang constraint defined as a sum of a Heaviside function which is incorporated into the objective function.

9. A method for automatically modifying a 3-Dimensional (3D) object model, the method comprising:
obtaining an input 3D object model comprising an input 3D mesh;
analyzing the input 3D mesh to identify unprintable overhangs that have an angle over an overhang angle limit and identify vertices associated with the unprintable overhangs as active vertices; and
performing an optimization process to move the active vertices of the input 3D mesh to eliminate the unprintable overhangs and generate an output 3D mesh, wherein the optimization process is divided into a series of suboptimizations that each generate a modified 3D mesh resulting, eventually, the output 3D mesh;
wherein performing the optimization process comprises:
performing a gradient descent search algorithm on an objective function, wherein the objective function comprises a cost function that represents a difference between the input 3D mesh and the modified 3D mesh, and wherein the gradient descent search algorithm is to minimize the objective function to minimize the difference between the input 3D mesh and the modified 3D mesh subject to an overhang constraint comprising an optimization angle related to the overhang angle limit, wherein the modified 3D mesh is determined by multiplying a gradient of the objective function by a step size;
performing a topology validation process to determine whether the modified 3D mesh is invalid due to an intersection of portions of the modified 3D mesh; and
responsive to determining that the modified 3D mesh is not invalid and that the optimization angle is over the overhang angle limit, reducing the optimization angle to be used for the overhang constraint in the next suboptimization by an increment based on the step size.

10. The method of claim 9 , wherein the objective function further comprises a pseudo-energy regularization term configured to avoid mesh deformation.

11. The method of claim 10 , wherein the pseudo-energy regularization term is based on sphere packing.

12. The method of claim 9 , wherein the overhang constraint comprises a face overhang constraint that constrains an angle between a build direction and a normal vector of each face in the modified 3D mesh to be less than the overhang angle limit.

13. The method of claim 9 , wherein the overhang constraint comprises an edge overhang constraint that constrains an angle between a build direction and each edge in the modified 3D mesh to be less than the overhang angle limit.

14. The method of claim 9 , wherein the overhang constraint comprises a stalactite constraint imposed on any downward facing vertex of the modified 3D mesh to ensure that the downward facing vertex is not a local minimum among its neighboring vertices.

15. The method of claim 9 , wherein the gradient descent search algorithm is further subject to an outward constraint that restricts movement of any vertex in the modified 3D mesh to be in an outward directed compared to a surface of the input 3D mesh.

16. The method of claim 9 , wherein the overhang constraint is a weak form of a face overhang constraint defined as a sum of a Heaviside function which is incorporated into the objective function.

17. A non-transitory computer-readable storage medium having instructions stored thereon that, when executed by a processing device for automatically modifying a 3-Dimensional (3D) object model, cause the processing device to:
obtain an input 3D object model comprising an input 3D mesh;
analyze the input 3D mesh to identify unprintable overhangs that have an angle over an overhang angle limit and identify vertices associated with the unprintable overhangs as active vertices; and
perform an optimization process to move the active vertices of the input 3D mesh to eliminate the unprintable overhangs and generate an output 3D mesh, wherein the optimization process is divided into a series of suboptimizations that each generate a modified 3D mesh resulting, eventually, the output 3D mesh;
wherein at each suboptimization, the processing device is to:
perform a gradient descent search algorithm on an objective function, wherein the objective function comprises a cost function that represents a difference between the input 3D mesh and the modified 3D mesh, and wherein the gradient de

Assignees

• Palo Alto Res Ct Inc
• Xerox Corp

Inventors

• Chen Jiangce
• Behandish Morad
• Patterson Matt

Classifications

• G06T19/20

  Editing of three-dimensional [3D] images, e.g. changing shapes or colours, aligning objects or positioning parts · CPC title

• G05B19/4099 Primary

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

• B33Y50/00

  Data acquisition or data processing for additive manufacturing · CPC title

• G05B2219/49023

  3-D printing, layer of powder, add drops of binder in layer, new powder · CPC title

• G06T2219/2021

  Shape modification · CPC title