System for visualizing a three dimensional (3D) model as printed from a 3D printer

Patent metadata

Field	Value
Publication number	US-9946816-B2
Application number	US-201414217811-A
Country	US
Kind code	B2
Filing date	Mar 18, 2014
Priority date	Mar 18, 2014
Publication date	Apr 17, 2018
Grant date	Apr 17, 2018

Abstract

A system and a method visualize three dimensional (3D) printability of a 3D model. A 3D printing process of the 3D model is simulated to generate a layered 3D model describing the 3D model as printed. A visual rendering of the layered 3D model is generated, and the visual rendering of the layered 3D model is displayed on a display device.

First claim

What is claimed is:

1. A system for visualizing three dimensional (3D) printability of a 3D model, said system comprising:
at least one processor configured to:
simulate an actual 3D printing process of the 3D model to generate a layered simulated 3D model describing the 3D model as it is to be printed, wherein operations to simulate the actual 3D printing process of the 3D model includes for the simulation, (i) selection of a printing material to be used in the actual 3D printing process and for the simulation, (ii) selection of (a) a type of 3D printing process to be used in the actual 3D printing process, (b) a thickness of layers for the actual 3D printing process, and (c) a smallest printable feature defined by one of a nozzle and a laser beam to be used in the actual 3D printing process;
generate a visual rendering of the layered simulated 3D model including highlighting of regions of the layered simulated 3D model differing from the 3D model, wherein the 3D model is an originally received model; and
display the visual rendering of the layered simulated 3D model on a display device, wherein the layered 3D model is generated with unprintable regions and displayed with color coding to allow a user to identify defects in the original 3D model;
control a 3D printer to physically print the 3D model according to the layered simulated 3D model.

2. The system according to claim 1 , wherein the at least one processor is further configured to:
receive or generate slices of the 3D model, the slices representing two dimensional (2D) solids of the 3D model to be printed in corresponding print layers;
simulate printing of the slices to identify corresponding printable slices; and
combine the printable slices into the layered simulated 3D model.

3. The system according to claim 2 , wherein the at least one processor is further configured to:
generate one of the slices by intersecting a 2D plane with a normal parallel to a build orientation of the 3D model at a height of the corresponding print layer.

4. The system according to claim 2 , wherein the simulation simulates printing of one of the slices to identify a corresponding printable slice by translating the smallest printable feature within a boundary of the slice or along a user-defined tool path, wherein the smallest printable feature is modeled with a circular disc, allowing computations to be directly formulated on polygons that define the boundary of the slice.

5. The system according to claim 2 , wherein the simulation simulates printing of one of the slices to identify a corresponding printable slice by calculating a morphological opening of the slice by a structuring element representing the smallest printable feature.

6. The system according to claim 2 , wherein the combining includes:
extruding the printable slices in a print direction by a distance equal to layer thickness of 3D printing process; and
placing the extruded printable slices in the layered simulated 3D model at heights of the corresponding print layers.

7. The system according to claim 1 , wherein the at least one processor is further configured to:
generate a displacement map, as part of the simulation of the actual 3D printing process, mapped to a surface of the layered simulated 3D model from a shape of a segment of 3D printed material generated according to the 3D printing process, wherein the displacement map is given by an image, data in the image determining displacement geometry at a stage of rendering pixels, and the data being used to calculate normals per-pixel to compute lighting effects and to calculate displacement to determine which part of the geometry will be visible to a camera for each pixel that is rendered, wherein noise is incorporated into an image defining the displacement map, an amount of the noise incorporated being determined to reflect roughness inherent in surfaces of an object produced by the actual 3D printing process; and
generate the visual rendering with the displacement map.

8. The system according to claim 1 , wherein the at least one processor is further configured to:
select a material shader for a print material selected by a user; and
generate the visual rendering with the material shader.

9. The system according to claim 1 , wherein the at least one processor is further configured to:
receive or generate slices of the 3D model, the slices representing two dimensional (2D) solids of the 3D model to be printed in corresponding print layers;
simulate printing of the slices to identify corresponding printability maps, the printability maps partitioning the slices into at least two sets of disjoint regions, the at least two sets of regions including a set of regions formed of features smaller than a minimum printable feature and a set of regions formed of features larger than the minimum printable feature;
combine the printability maps into the layered simulated 3D model; and
generate a visual rendering of the layered simulated 3D model in which the at least two sets of regions are displayed differently.

10. The system according to claim 1 , wherein the at least one processor includes a plurality of processors, and wherein the plurality of processors are configured to simultaneously simulate printing of multiple layers of the 3D model in parallel to generate the layered simulated 3D model.

11. A method for visualizing three dimensional (3D) printability of a 3D model, said method comprising:
simulating by at least one processor an actual 3D printing process of the 3D model to generate a layered simulation 3D model describing the 3D model as it is to be printed, wherein operations to simulate the actual 3D printing process of the 3D model includes, for the simulation, (i) selection of a printing material to be used in the actual 3D printing process and, for the simulation, (ii) selection of (a) a type of actual 3D printing process to be used in the actual 3D printing process, (b) a thickness of layers of the actual printing process in the actual 3D printing process, and (c) a smallest printable feature defined by one of a nozzle and a laser beam to be used in the actual 3D printing process for the simulation;
generating by the at least one processor a visual rendering of the layered simulated 3D model including highlighting of regions of the layered simulated 3D model differing from the 3D model, wherein the 3D model is an originally received model; and
displaying by the at least one processor the visual rendering of the layered 3D model on a display device, wherein the layered 3D model is generated with unprintable regions and displayed with color coding to allow a user to identify defects in the original 3D model;
controlling a 3D printer to physically print the 3D model according to the layered simulated 3D model.

12. The method according to claim 11 , further including
receiving or generating slices of the 3D model, the slices representing two dimensional (2D) solids of the 3D model to be printed in corresponding print layers;
simulating printing of the slices to identify corresponding printable slices; and
combining the printable slices into the layered simulated 3D model.

13. The method according to claim 12 , further including:
generating one of the slices by intersecting a 2D plane with a normal parallel to a build orientation of the 3D model at a height of the corresponding print layer.

14. The method according to claim 12 , wherein the simulation simulates printing of one of the slices to identify a corresponding printable slice by translating the smallest printable feature within a boundary of the slice or along a user-defined tool path and

Assignees

• Palo Alto Res Ct Inc

Inventors

• Kim Walter
• Kurtoglu Tolga
• Nelaturi Saigopal
• Rangarajan Arvind

Classifications

• G06T2219/008

  Cut plane or projection plane definition · CPC title

• G06T17/00

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

• G06F30/20 Primary

  Design optimisation, verification or simulation (optimisation, verification or simulation of circuit designs G06F30/30) · CPC title

• G06T19/00 Primary

  Manipulating three-dimensional [3D] models or images for computer graphics · CPC title

• G06F2113/10

  Additive manufacturing, e.g. three-dimensional [3D] printing · CPC title