Systems and methods for optimization of 3-d printed objects

Patent metadata

Field	Value
Publication number	US-2018321659-A1
Application number	US-201615773235-A
Country	US
Kind code	A1
Filing date	Nov 5, 2016
Priority date	Nov 6, 2015
Publication date	Nov 8, 2018
Grant date	—

Abstract

The present subject matter includes systems, methods, and devices for optimization of objects generated using 3-D printing. A printed object may be optimized for performance, such as increasing the strength of the object while retaining the shape of the object. For example, if the object is an object designed for a three-point bend, optimization may include removing material from regions within the object to change the relative densities and stiffness in each of the regions while retaining the original shape of the object. Optimization of an object while retaining the object shape enables the object to function and to appear as it was origin ally designed, and to continue to interact with neighboring components in the same way.

First claim

1 . A method for optimizing a three-dimensional object printing model, the method comprising:
receiving a three-dimensional (3-D) digital model; identifying a plurality of stress regions based on the digital model; identifying a plurality of 3-D printing regions in which at least a fine fill, a coarse fill, and a coarser fill, each relative to each other, are to be used based on the identified plurality of stress regions to provide a gradually varying structure; and storing the plurality of 3-D printing regions in an optimized 3-D object printing model.

2 . The method of claim 1 , further including receiving a defined design architecture constraint, the defined design architecture constraint including at least one of a digital model deformation constraint and a digital model deflection constraint.

3 . The method of claim 2 , wherein:
identifying a first stress region and identifying a second stress region within the digital model; and identifying a first printing region and identifying a second printing region within the digital model, the identification of the first and second printing regions based on the identification of the first and second stress regions.

4 . The method of claim 3 , wherein:
identifying the first printing region includes determining a first printing region location and determining a first 3-D printing material; and identifying the second printing region includes determining a second printing region location and determining a second 3-D printing material, the first material being different from the second material.

5 . The method of claim 4 , further including determining a first 3-D printing bead route based on an expected contraction associated with the first 3-D printing material.

6 . The method of claim 4 , wherein the second material includes a fiber-reinforced material.

7 . The method of claim 6 , wherein the fiber-reinforced material includes a chopped fiber material.

8 . A system for optimizing a three-dimensional (3-D) object printing model, the system including:
a memory; and a processor configured to:
receive a three-dimensional (3-D) digital model;
identify a plurality of stress regions based on the digital model;
identify a plurality of 3-D printing regions in which at least a fine fill, a coarse fill, and a coarser fill, each relative to each other, are to be used based on the identified plurality of stress regions to provide a gradually varying structure; and
store the plurality of 3-D printing regions in an optimized 3-D object printing model on the memory; and
a 3-D printing mechanism configured to print the plurality of 3-D printing regions.

9 . The system of claim 8 , the 3-D printing mechanism including:
a material deposition device to form a deposited layer; and a reinforcement placement device configured to apply a reinforcement material to the deposited layer.

10 . The system of claim 8 , wherein the 3-D printing mechanism is mounted on at least one of a gantry and a robotic arm.

11 . The system of claim 8 , the processor further configured to receive a defined design architecture constraint.

12 . The system of claim 11 , wherein the defined design architecture constraint includes a material distribution optimization, the material distribution optimization including at least one of a reduced printed object weight constraint and an increased printed object stiffness constraint.

13 . The system of claim 11 , the processor further configured to:
identifying a first stress region and identifying a second stress region within the digital model; and identifying a first printing region and identifying a second printing region within the digital model, the identification of the first and second printing regions based on the identification of the first and second stress regions.

14 . The system of claim 13 , the processor further configured to:
identifying the first printing region includes determining a first printing region location and determining a first 3-D printing material; and identifying the second printing region includes determining a second printing region location and determining a second 3-D printing material, the first material being different from the second material.

15 . The system of claim 14 , wherein the second material includes a fiber-reinforced material.

16 . The method of claim 1 , wherein the 3-D printing regions in which the fine fill, the coarse fill, and the coarser fill are to be used correspond to a high stress region, a medium stress region, and a low stress region, respectively.

17 . The method of claim 1 , wherein the fine fill comprises at least one of a fine vertical fill and a fine horizontal fill, wherein the coarse fill comprises at least one of a coarse vertical fill and a coarse horizontal fill, and wherein the coarser fill comprises at least one of a coarser vertical fill and a coarser horizontal fill.

18 . The system of claim 8 , wherein the 3-D printing regions in which the fine fill, the coarse fill, and the coarser fill are to be used correspond to a high stress region, a medium stress region, and a low stress region, respectively.

19 . The system of claim 8 , wherein the fine fill comprises at least one of a fine vertical fill and a fine horizontal fill, wherein the coarse fill comprises at least one of a coarse vertical fill and a coarse horizontal fill, and wherein the coarser fill comprises at least one of a coarser vertical fill and a coarser horizontal fill.

20 . The system of claim 8 , wherein the 3-D printing mechanism comprises a compounding system.

Assignees

• Sabic Global Technologies Bv

Inventors

• Dasappa Prasad
• Pozhal Vengu Gurunath
• Agarwal Aravinda
• Harding Gerould
• Ly Kim Loan Thi

Classifications

• B33Y30/00

  Apparatus for additive manufacturing; Details thereof or accessories therefor · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29C70/38

  Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns {(application heads for tyres B29D30/28)} · CPC title

• G06F2119/18

  Manufacturability analysis or optimisation for manufacturability · CPC title

• B33Y50/00

  Data acquisition or data processing for additive manufacturing · CPC title