Beam lattice data in additive manufacturing

Patent metadata

Field	Value
Publication number	US-2022347926-A1
Application number	US-202017621124-A
Country	US
Kind code	A1
Filing date	Apr 28, 2020
Priority date	Jul 15, 2019
Publication date	Nov 3, 2022
Grant date	—

Abstract

In an example a method includes receiving, at processing circuitry, beam lattice data modelling at least part of a three-dimensional object to be generated using additive manufacturing as a beam lattice. A volumetric data model may be determined from the beam lattice data. Determining the volumetric data model may comprise dividing a volume containing the beam lattice data into sub-volumes and categorising the sub-volumes into (I) interior sub-volumes, which are wholly within a beam of the beam lattice; (ii) exterior sub-volumes which are wholly outside the beams of the beam lattice; and (ii) boundary sub-volumes which partially coincide with a beam of the beam lattice. The method may further comprise subdividing boundary sub-volumes and categorising the subdivided sub-volumes until a threshold volume size of boundary sub-volume is reached.

First claim

1 . A method comprising:
receiving, at processing circuitry, beam lattice data modelling at least part of a three-dimensional object to be generated using additive manufacturing as a beam lattice; determining, using processing circuitry, a volumetric data model from the beam lattice data, wherein determining the volumetric data model comprises: dividing a volume containing the beam lattice data into sub-volumes; and categorising the sub-volumes into:
interior sub-volumes, which are wholly within a beam of the beam lattice;
exterior sub-volumes which are wholly outside the beams of the beam lattice; and
boundary sub-volumes which partially coincide with a beam of the beam lattice; the method further comprising:
subdividing boundary sub-volumes and categorising the subdivided sub-volumes until a threshold volume size of boundary sub-volume is reached.

2 . A method according to claim 1 wherein categorising the sub-volumes comprises determining, for each corner of the sub volume, if the corner coincides with a beam of the beam lattice wherein the method comprises;
if all the corners thereof are interior to a given beam, categorising the sub-volume as an interior sub-volume;
if all the corners thereof are outside the beams of the beam lattice, determining if any beams intersect with the volume of the sub-volume, and if not, categorising the sub-volume as an exterior sub-volume; and
if at least one corner is interior to a beam and at least one corner is exterior to that beam, or if all corners are outside the beams of the beam lattice and at least one beam intersects with the volume of the sub-volume, categorising the sub-volume as a boundary sub-volume.

3 . A method according to claim 1 further comprising:
categorising boundary sub-volumes of the threshold size as interior or exterior sub-volumes by determining a first number of corners which are interior to a beam, and a second number of corners which are exterior to the beams, and determining the categorisation based on the first and second number.

4 . A method according to claim 1 further comprising determining a capping mode of the beam lattice and wherein a volumetric extent of the beams of the beam lattice used in determining which sub-volumes are wholly within a beam of the beam lattice, which sub-volumes are wholly outside the beams of the beam lattice and which sub-volumes partially coincide with a beam of the beam lattice is determined based on the capping mode.

5 . A method according to claim 1 further comprising determining if the model is to be clipped and, if so to apply a clipping mask to the volumetric model to remove a portion of the model; and
where the clipping mask intercepts an interior sub-volume which is greater than the threshold size the method further comprises:
dividing the intercepted sub-volume into further sub-volumes and categorising the further sub-volumes by determining if the further sub-volumes are wholly interior to the clipped model, wholly exterior to the clipped model or span a boundary of the clipped model.

6 . A method according to claim 1 further comprising determining print instructions for generating an object based on the categorised sub-volumes.

7 . A method according to claim 6 further comprising generating an object using the print instructions.

8 . An apparatus comprising processing circuitry, the processing circuitry comprising:
an object model transformation module to transform a data model of a three-dimensional object to be generated from a first model defined using a beam lattice to a second model defined using a plurality of contiguous, non-overlapping sub-volumes; wherein the object model transformation module is to recursively sub-divide a virtual volume containing the first model until the sub-volumes thereof can be categorised as:
interior sub-volumes, which are wholly within a beam of the beam lattice;
exterior sub-volumes which are wholly outside the beams of the beam lattice; or
sub-volumes having a predetermined minimum size.

9 . An apparatus according to claim 8 further comprising a clipping module wherein the clipping module is to apply a boundary mask to the sub-volumes to remove a portion of the model and, where the boundary mask intercepts an interior sub-volume,
the object model transformation module is to divide and categorise the intercepted sub-volume.

10 . An apparatus according to claim 8 wherein the object model transformation module is to categorise each sub-volume by determining if the corners thereof are interior or exterior to the beams.

11 . An apparatus according to claim 10 wherein, when all the corners of a sub volume are exterior to the beams, the object model transformation module is to determine if any beams intersect the sub-volume and, if not, to categorise the sub-volume as an exterior sub-volume.

12 . An apparatus according to claim 8 wherein the object model transformation module is to categorise each sub-volume by determining a volumetric extent of a beam based on a capping mode associated with the beam.

13 . Apparatus according to claim 8 further comprising a control data module to determine additive manufacturing apparatus control data to generate an object from the categorised sub-volumes.

14 . Apparatus according to claim 13 further comprising additive manufacturing apparatus to generate at least one object using the additive manufacturing apparatus control data.

15 . Tangible machine-readable medium storing instructions which, when executed by a processor, cause the processor to:
process data representing a first object as a virtual object comprising a beam lattice to determine a volumetric model of the virtual object, wherein the volumetric model of the virtual object is described using a plurality of sub-volumes by classifying each sub-volume as one of an interior sub-volume and a boundary sub-volume if a beam of the virtual object intersects with the region defined by the sub-volume; and if the sub-volume is a boundary sub-volume of above a threshold size, to subdivide the sub-volume and classify the subdivided sub-volumes.

Assignees

• Hewlett Packard Development Co

Inventors

• Vinacua Pla Alvaro
• Chica Calaf Antonio
• Carruesco Llorens Alex
• Gonzalez Rogel Jordi
• Giralt Garcia Oriol
• Gonzalez Martin Sergio
• Ballesteros Brandao Joao Hugo
• Martin Garcia Pol
• Kazatzis Konstantinos

Classifications

• B33Y50/00 Primary

  Data acquisition or data processing for additive manufacturing · CPC title

• B29C64/386 Primary

  Data acquisition or data processing for additive manufacturing · CPC title

• G05B19/4099

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

• Y02P10/25

  Process efficiency · CPC title

• G06T17/00

  Three-dimensional [3D] modelling for computer graphics · CPC title