BE1023316B1 - Systems and methods for optimizing contact points of tree-shaped supports in additive manufacturing - Google Patents

Abstract

Systems and methods for optimizing tree support contact points in additive manufacturing are described. The systems and methods involve analyzing an object to determine support needed and defining a trunk for a tree support. The trunk is anchored to a platform and connection points are determined for at least one branch of the tree support. Subsequently, connection types and parameters for branch connections to the surface of the object can be selected and the at least one branch is then connected to the surface of the part and the trunk to create the tree-shaped support.

Description

Systems and methods for optimizing contact points of tree-shaped supports in additive manufacturing

Background of the Invention Field of application of the invention

The present invention generally relates to techniques of additive manufacturing and / or three-dimensional (3d) printing.

Description of the technology involved

Additive manufacturing and / or three-dimensional printing techniques offer the possibility to produce three-dimensional objects, directly from computer-generated files. The techniques of additive manufacturing often offer the possibility of producing both simple and complex objects without further processing.

In a number of additive manufacturing techniques, high amounts of stresses and loads can be applied to the process of forming or generating the three-dimensional object. Thermal and / or mechanical stresses and / or loads can occur due to the high temperature of an energy source that is used in the generation of the three-dimensional object. The produced object can also be subjected to mechanical stresses and / or loads due to the properties of the material specifically used in the additive manufacturing process. These properties may include the shrinking or expansion of the material occurring when the material is being treated.

In one specific example, strong stresses and / or loads occur in the processing of metal and metal powders when using processing techniques such as direct metal laser sintering, laser hardening, and selective laser melting or sintering. These stresses and / or loads of the object can cause certain parts of the object to deform during construction, which can lead to a defect in forming or to an object that is defective. Accordingly, it is sometimes beneficial to use supports in the course of the forming process to hold the object in place and / or to prevent distortions.

When using a support to hold the object in place and / or to prevent distortions of the object, a number of problems arise. For example, it can be expensive to create a support large enough to support the three-dimensional object, due to the cost of the materials needed to generate the support. Furthermore, removal of the support from the object in the course of post-processing after the object has been produced is expensive, it can leave a residue on the object and / or damage the object.

Against the background of these and other defects found by the inventors, there is a need for systems and methods for optimizing contact points of tree-shaped supports in additive manufacturing.

Summary

Numerous implementations of systems, methods and devices that fall within the scope of the appended claims each have different aspects, none of which is solely responsible for the desired attributes described in this text. Without wishing to limit the scope of this application as expressed in the following claims, a number of important features will be described below. Having considered this description, in particular after reading the section entitled "Detailed Description of Certain Embodiments of the Invention", it will be understood how the features of this invention offer various advantages compared to conventional systems and methods. of additive manufacturing and three-dimensional printing.

In one embodiment, systems and methods for optimizing contact points for tree-shaped supports in additive manufacturing are described. The systems and methods are associated with analyzing an object to determine required supports and defining a trunk for a tree-shaped support. The trunk is anchored to a platform and connection points are determined for at least one branch of the tree-shaped support. Subsequently connection types and parameters for branch connections to the surface of the object can be selected and the at least one branch is then connected to the surface of the part and the trunk to create the tree-shaped support.

Brief description of the drawings

These and other features, aspects and advantages of the invention described in this publication are described in what follows with reference to the drawings of preferred embodiments which are intended to be illustrative and which are not intended to limit the invention. Moreover, the same reference numerals were used in the various figures to indicate the same components of an illustrated embodiment. The following is a brief description of each of the drawings.

Figure 1 is a block diagram that provides a high-level illustration of a system that can be used to design and produce three-dimensional (3D) objects.

Figure 2 is a functional block diagram of one example of a computer from Figure 1.

Figure 3 is a high-level example of a process for the production of a three-dimensional object.

Figure 4 is a schematic illustration of a three-dimensional printing machine that can be used to perform the techniques described in this text according to one or more embodiments.

Figure 5 is a high-level block diagram of various aspects of an additive manufacturing system that can be used to implement various embodiments described in this text.

Figure 6 is a block diagram that provides a more detailed view of the 3D data preparation and STL editing module of Figure 5.

Figure 7 is a block diagram that provides a more detailed view of the part support and anchoring module of Figure 6.

Figure 8 is a graphic illustration of an elementary tree-shaped support that can be used to support zones of an object that is subjected to stresses or loads in the course of an additive manufacturing process.

Figure 9 is a graphical illustration of a customized tree-shaped support that can be used in accordance with one or more embodiments.

Figure 10 is an example of a graphical user interface environment that can be used to define one or more parameters of the trunk of a tree-shaped support in accordance with one or more embodiments.

FIG. 11A-11D provide an example of a graphical user interface environment that can be used to define one or more parameters of the branches of a tree-shaped support in accordance with one or more embodiments. Fig. 12 is a flow chart illustrating a process by which an object can be produced with defined tree-shaped supports in accordance with one or more embodiments.

Figure 13 is a flowchart illustrating a process for selecting connection types and parameters for branch connections to the surface of the part in accordance with one or more embodiments.

Detailed description of certain embodiments of the invention

The following detailed description and the accompanying figures are directed to certain specific embodiments. The embodiments described in any specific context are not intended to limit this publication to the specified embodiment or to any specific use. Those skilled in the art will appreciate that the described embodiments, aspects and / or features are not limited to any specific embodiments. The devices, systems and methods described in this text can be designed and optimized for use in a variety of domains.

The reference throughout this specification to "one embodiment", "an embodiment", "some aspects", "an aspect" or "one aspect" means that a specific characteristic, a specific structure or a specific characteristic described in connection with the embodiment or the aspect is contained in at least one of the embodiments of the present invention. The terms "in one embodiment", "in one embodiment", "some aspects", "one aspect" or "one aspect" when occurring at different locations throughout the specification therefore do not necessarily all refer to the same embodiment or same aspect, although that may also be the case. In addition, the specific features, structures or properties can be combined in any suitable manner, as will be apparent to those skilled in the art, and in one or more combinations or aspects. In addition, while some of the embodiments or aspects described herein include some but not all of the features contained in other embodiments or aspects, combinations of features of different embodiments or aspects are intended to be within the scope of the invention, and form, as it will be are recognized by people in the field, different embodiments or aspects. By way of example, in the appended claims, any of the features of the embodiments or aspects described in the claims may be used in any combination.

Those skilled in the art will appreciate that the techniques and methods described in this text can be implemented using different systems of additive manufacturing and / or three-dimensional (3D) printing. Similarly, the products formed by the techniques and methods described in this text can be formed by various systems and materials of additive manufacturing and / or three-dimensional printing. In general, techniques of additive manufacturing or three-dimensional printing start a digital representation of the three-dimensional object to be formed. The digital representation is usually divided into a series of sectional layers that are superimposed to form the object as a whole. The layers represent the three-dimensional object and can be generated using additive manufacturing modeling software performed by a computer device. The software may, for example, include computer aided design and manufacturing (CAD / CAM) software. Information about the sectional layers of the three-dimensional object can be stored in the form of sectional data. A machine or system of additive manufacturing or three-dimensional printing makes use of the cross-sectional data with a view to forming the object layer after layer. In the same way, additive manufacturing or three-dimensional printing allows three-dimensional objects to be produced, directly from computer-generated data, for example, computer aided design (CAD) files. Additive manufacturing or three-dimensional printing offers the possibility to produce both simple and complex objects without further processing and without the need to assemble different parts.

Examples of additive manufacturing and / or three-dimensional printing include stereolithography, selective laser sintering, fused deposition modeling (EDM), foil-based techniques, etc. Stereolithography ("SLA"), by way of example, uses a liquid photopolymer container "resin" to form an object one layer at a time. Each layer contains a section of the object to be formed. First a layer of resin is deposited over the entire forming zone. For example, a first layer of resin can be deposited on a base plate of an additive manufacturing system. An electromagnetic beam then scans a specific pattern on the surface of the liquid resin. The electromagnetic beam can be delivered in the form of one or more laser beams that are controlled by the computer. Exposure of the resin to the electromagnetic beam hardens the pattern that is followed by the electromagnetic beam and causes the resin to adhere to the layer below. After a layer of resin has been polymerized, the platform descends with the thickness of a single layer and a subsequent layer of resin is deposited. A pattern is followed on each layer of resin, and the newly followed layer pattern adheres to the previous layer. By repeating this process, a complete three-dimensional object can be formed. The hardened three-dimensional object can be removed from the SLA system and further processed in post-processing.

Selective laser sintering ("SLS") is another additive manufacturing technique that uses a high-power laser or other concentrated energy source to fuse small fusible particles of the curable material. In a number of embodiments, selective laser sintering can also be called "selective laser melting". In a number of embodiments, the high power laser may be a carbon dioxide laser for use in the processing of, for example, polymers. In a number of embodiments, the high-power laser may be a fiber laser for use in the processing of, for example, metal materials. Those skilled in the art will appreciate that in a number of embodiments other types of high power laser can also be used based on the specific application. The particles can be fused by sintering or welding the particles together using the high power laser. The small fusible particles of the curable material can be made from plastic powders, polymer powders, metal (direct metal laser sintering) powders, or ceramic powders (e.g. glass powders and the like). The fusion of these particles produces an object that exhibits a desired three-dimensional shape. A first layer of powder material can for example be deposited on a base plate. A laser can be used to selectively fuse the first layer of powder material by scanning the powder material for the purpose of creating and forming a first cross-sectional layer of the three-dimensional object. After each layer has been scanned and each cross-sectional layer of the three-dimensional object has been formed, the powder bed can be lowered by one layer of thickness, a new layer of powder material can be deposited on top of the previous layer, and the process can be repeated until production is completed and the object has been generated. The sectional layers of the three-dimensional object can be generated using a digital three-dimensional description of the desired object. The three-dimensional description can be supplied by a CAD file or by means of scanned data entered into a computer device. The hardened three-dimensional object can be removed from the SLS system and further processed in post-processing.

Additive manufacturing or three-dimensional printing systems include, but are not limited to, various implementations of SLA and SLS technology. The materials used may contain, but are not limited to: polyurethane, polyamide, polyamide with additives such as glass or metal particles, resorbable materials such as polymer-ceramic composites, etc. Examples of commercially available materials include: DSM Somos® series 7100, 8100, 9100, 9420, 10100, 11100, 12110, 14120 and 15100 from DSM Somos; the line materials Accura Plastic, DuraForm, CastForm, Laserform and VisiJet from 3-Systems; aluminum, cobalt chrome and stainless steel materials; maraging steel; nickel alloy; titanium; the PA materials line, PrimeCast and PrimePart materials and Alumide and CarbonMide from EOS GmbH.

Various aspects will now be described with reference to specific forms or embodiments selected for illustrative purposes. It will be appreciated that the spirit and scope of the objects described in this text is not limited to the selected embodiments. In addition, it should be noted that the accompanying drawings are not drawn in any specific ratio or on any scale, and that numerous modifications can be made to the illustrated embodiments. In the following, brief introductions are described with respect to some of the features that may be common to the embodiments described in this text.

Figures 1-4 provide an example of general systems and methods that can be used for the additive manufacturing of three-dimensional objects. Initially with reference to Figure 1, an example of a system 100 is provided for designing and producing three-dimensional objects and / or products. The system 100 can be configured to support the techniques described in this text. The system 100 can be configured, for example, with a view to designing and producing a three-dimensional object and a corresponding support system such as any of the three-dimensional objects and corresponding support systems described in more detail below. In a number of embodiments, the system 100 may include one or more computers 102a-102d. The computers 102a-102d can take various forms, such as, for example, any workstation, any server or any other computer device that can process information. The computers 102a-102d can be connected through a computer network 105. The computer network 105 can be the internet or a LAN (local area network), a WAN (wide area network), or any other type of network. The computers can communicate with each other over the computer network 105 by any suitable communication technology or any suitable communication protocol. The computers 102a-102d can exchange data by sending and receiving information, for example, software, digital representations of three-dimensional objects, commands and / or instructions to operate an additive manufacturing device, etc.

The system 100 may further comprise one or more devices of additive manufacturing 106a and 106b. These additive manufacturing devices can take the form of 3D printers or any other production devices as known in the art. In the example illustrated in Figure 1, the device of additive manufacturing 106a is connected to the computer 102a. The device of additive manufacturing 106a is also connected to the computers 102a-102c through the network 105 that connects the computers 102a-102d. The device of additive manufacturing 106b is also connected by means of the network 105 to the computers 102a-102d. Those skilled in the art will appreciate that an additive manufacturing device such as devices 106a and 106b can be directly connected to a computer 102, can be connected to a computer 102 through a network 105, and / or can be connected to a computer 102 be connected via another computer 102 and through the network 105.

Although a specific computer and network configuration is described in Figure 1, those skilled in the art will also appreciate that the techniques of additive manufacturing described in this text can be implemented using a single-computer configuration that incorporates the additive manufacturing device 106 checks and / or supports, without the need for a computer network.

With reference to Figure 2, a more detailed illustration of the computer 102a of Figure 1 is provided. The computer 102a contains a processor 210. The processor 210 is in data communication with various computer components. These components may include a memory 220 as well as an input device 230 and an output device 240. In some embodiments, the processor may also communicate with a network interface card 260. Although described as a separate component, it should be understood that the functional blocks described are no different structural elements with respect to computer 102a. For example, the processor 210 and the network interface card 260 may be included in a single chip or a single board.

The processor 210 may be a universal processor or a digital signal processor (digital signal processor, DSP), an application-specific integrated circuit (application specific integrated circuit, ASIC), a field-programmable gate array (field programmable gate array, FPGA) or another programmable logic unit, a separate port or transistor, separate hardware components, or any combination thereof, to perform the functions described in this text. A processor can also be implemented as a combination of computer equipment, for example a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in combination with a DSP core, or any other such configuration.

The processor 210 can be coupled, via one or more buses, to read information from, or write to, the memory 220. The processor can additionally, or as another possibility, contain memory, e.g. processor registers. The memory 220 may contain processor cache, including a multi-level hierarchical cache in which different levels have different options and different access speeds. This memory 220 may further comprise a random access memory (RAM), as well as other devices with a volatile memory or devices with a non-volatile memory. The data storage can consist of hard disks, optical disks such as compact discs (CDs) or digital video discs (DVDs), flash memory, diskettes, magnetic tape, and Zip drives.

The processor 210 can also be coupled to an input device 230 and an output device 240 for resp. get input from, and deliver output to, a user of computer 102a. Suitable input devices include, but are not limited to, a keyboard, a rollerball, buttons, keys, switches, pointing devices, a mouse, a joystick, a remote control device, an infrared detector, a voice recognition system, a barcode reader, a scanner, a video camera ( possibly coupled to image processing software to detect, for example, hand or face movements, a motion detector, a microphone (possibly coupled to sound processing software to detect, for example, voice commands), or any other device capable of transmitting data from a user to a computer. The input device may also take the form of a touchscreen associated with the display, in which case a user responds to information displayed on the display by touching the screen. The user can enter information in the form of text by means of an input device such as a keyboard or the touchscreen. Suitable output devices include, but are not limited to, visual output devices, including screens and printers, audio output devices, including speakers, headphones, earphones and alarms, additive manufacturing devices, and haptic output devices.

The processor 210 may further be coupled to a network interface card 260. The network interface card 260 prepares data generated by the processor 210 for transmission via a network in accordance with one or more data transmission protocols. The network interface card 260 can also be configured for decoding data received by the network. In a number of embodiments, the network interface card 260 may include a transmitter, a receiver, or both a transmitter and a receiver. Based on the specific embodiment, the transmitter and the receiver may consist of a single integrated component or may be two separate components. The network interface card 260 can be in the form of a universal processor or a digital signal processor (digital signal processor, DSP), an application-specific integrated circuit (application-specific integrated circuit, ASIC), a field-programmable gate array ( field programmable gate array (FPGA) or another programmable logic unit, a separate gate or transistor, separate hardware components, or any combination thereof to perform the functions described in this text.

Using the devices described above with reference to Figures 1 and 2, a process of additive manufacturing can be applied to produce a three-dimensional object or a three-dimensional device. Figure 3 is an illustration of one such process. In particular, Figure 3 depicts a general process 300 for the production of a three-dimensional object and corresponding support system, as will be described in more detail with reference to Figures 5-19.

The process starts at step 305, where a digital representation of the three-dimensional object to be produced is designed using a computer, for example, the computer 102a. In a number of embodiments, a two-dimensional representation of the object can be used to create the three-dimensional model of the device. Alternatively, three-dimensional data may be entered into computer 1102a to aid in designing the digital representation of the three-dimensional object. The process continues until step 310, where information is sent from the computer 102a to an additive manufacturing device, e.g., the additive manufacturing device 106. Next, at step 315, the additive manufacturing device 106 begins to produce the three-dimensional object by carrying out a process of additive manufacturing with the use of suitable materials. Suitable materials include, but are not limited to, polypropylene, thermoplastic polyurethane, polyurethane, acrylonitrile-butadiene-styrene (ABS), polycarbonate (PC), PC-ABS, polyamide, polyamide with additives such as glass or metal particles, methyl methacrylate -acrylonitrile-butadiene-styrene copolymer, resorbable materials such as polymer-ceramic composites, and other similar suitable materials. Commercially available materials can be used in a number of embodiments. These materials can be, for example: the materials of the DSM Somos® series 7100, 8100, 9100, 9420, 10100, 11100, 12110, 14120 and 15100 from DSM Somos; Stratasys materials ABSplus-P430, ABSi, ABS-ESD7, ABS-M30, ABSM30i, PC-ABS, PC-ISO, PC, ULTEM 9085, PPSF and PPSU; the line materials Accura Plastic, DuraForm, CastForm, Laserform and VisiJet from 3D Systems; aluminum, cobalt chrome and stainless steel materials; maraging steel; nickel alloy; titanium; the PA materials line, PrimeCast and PrimePart materials and Alumide and CarbonMide from EOS GmbH. Using the appropriate materials, the additive manufacturing device then ends the process at step 320 where the three-dimensional object is generated.

Using a process 300 described with reference to Figure 3, a three-dimensional object and a corresponding support system can be produced by means of a three-dimensional printing machine that implements one or more additive manufacturing techniques. Figure 4 is a schematic illustration of one example of a three-dimensional printing machine 400 that can be used to perform the processes and / or techniques described in this text. In a number of embodiments, the three-dimensional printing machine 400 corresponds to one of the devices of additive manufacturing 106a or 106b as illustrated in Figure 1. The three-dimensional printing machine 400 can be configured for performing selective laser sintering to perform a three-dimensional object. to generate. The three-dimensional printing machine 400 may include a container 405 with curable material, for example, a powder material 407. The powder material 407 contains a plurality of powder particles that are at least partially fused together when struck by an energy source 410, e.g. multiple laser beams controlled by a computer. The particles can be made of plastic powders, polymer powders, metal powders (direct metal laser sintering), ceramic powders, glass powders, etc. The energy source 410 can be a programmable energy source that can be configured with a view to applying different amounts of energy at different speeds. and at a different pitch on the powder material 407. The energy source 410 may, for example, be a high-power laser or a carbon dioxide laser. A controller 420 can control the energy source 410. In a number of embodiments, the controller 420 corresponds to one of the computers 102a-102d illustrated in Figure 1 and / or the processor 210 illustrated in Figure 2. Those skilled in the art will appreciate that in a number of embodiments, the three-dimensional printing machine 400 also can be configured for performing stereolithography or any other additive manufacturing technique to generate a three-dimensional object and that the container 405 can contain another type of the curable material, for example a liquid resin.

In a number of embodiments, a digital representation of the three-dimensional object to be formed is input to the three-dimensional printing machine 400. Using the digital representation of the three-dimensional object to be formed, a digital representation of a support system for the specific three-dimensional object can be automatically generated by the controller 420 and / or other hardware or software. The digital representations of the three-dimensional object to be formed and the corresponding support system are subdivided into a series of sectional layers that can be superimposed to form the object and the support system in this way. Data representing the sectional layers can be stored in one or more computer files. The controller 405 can use this data to form the object and the support system layer after layer. The data of the sectional layers of the three-dimensional object and the support system can be generated using a computer system and computer aided design and manufacturing (CAD / CAM) software.

The data files for the three-dimensional object and the support system can be programmed or entered into the three-dimensional printing machine 400. A first layer of the powder material 407 can be deposited on a base plate 430. Based on the input data files, the three-dimensional printing machine 400 can guide the computer-controlled energy source 410 over the surface of the first layer of the powder material 407 to provide a first cross-sectional layer generating the three-dimensional object as well as a first cross-sectional layer of each support structure of the support system. By way of example, a high-power laser can be used for selectively fusing the particles of the layer by sintering or welding the particles to create the first cross-sectional shape of the three-dimensional object as well as the first cross-sectional layer of any support structure of the support system. The base plate 430 and the object can then be lowered to a depth corresponding to the desired thickness of the next sectional layer of the object. A roller or other transport mechanism may cause a subsequent layer of powder material 407 to be deposited from a reservoir (not in the drawing) in the container 405 over the previous sectional layer. The controller 420 can then direct the energy source 410 to the next layer of powder material 407 for the purpose of generating the next cross-sectional layer of the three-dimensional object and the next cross-sectional layer of each support structure of the support system. The process can be repeated until the formation is complete and the object and the support system have been generated.

The objects formed by the general techniques of additive manufacturing as described above exhibit a tendency to deviate from the desired dimensions of the object. For example, high amounts of stresses and loads can occur in the course of forming or generating the three-dimensional object by means of the techniques of additive manufacturing. For example, thermal and / or mechanical stresses and / or loads may occur in the course of an SLS process due to a high temperature of an energy source used in the generation of the three-dimensional object. For example, strong temperature differences can occur as a result of melting of the powders used in the SLS process, for example powders consisting of metal alloys, and these temperature differences can lead to thermal stresses and / or loads on the object. Internal mechanical stresses and / or loads can also be caused in the object itself due to the properties of the specific material used. These mechanical stresses and / or loads can, for example, take the form of shrinking or expanding the material used to form the object when that material is scanned by the energy source. Strong stresses and / or loads on the object can cause certain parts of the object to deform during construction, which can lead to production interruption or to an inaccurate object or defective object. For example, a powder coater in an SLS machine may hit a deformed portion of the object and / or the dimensional accuracy of the object may be adversely affected.

Various supports can be used to hold the object in place and / or to prevent distortions of the object in the course of the forming process. However, problems may arise when using these supports. For example, it can be expensive to create a support that is stable enough to support the three-dimensional object, due to the cost of the materials needed to generate the support. Furthermore, removing the support from the three-dimensional object in the course of post-processing after the object has been produced is expensive, can leave a residue on the object and / or can damage the object. Tree-shaped supports are currently used to support parts. In most cases, the connection is a straight line between the top of the trunk and the contact point, or connection, on the part. As a result, each branch connection is different since each connection is positioned at a different angle. However, if the supports are not uniformly connected to the surface of the part, the part can be damaged when the support is removed.

Against the background of the aforementioned shortcomings, the inventors have found that there is a need for systems and methods to optimize the contact points of tree-shaped supports in additive manufacturing to provide a uniform connection between trees and the object, or part, for a clean and facilitate easy removal of the tree which minimizes damage to the part. With this in mind, new and inventive systems and methods are proposed in this text. In at least one embodiment of the invention, the branch of a tree-shaped support system may be designed to display a break-off point or not. The break-off points can be connected to the part in a manner: (1) perpendicular to the connection point; (2) vertically (perpendicular to the platform); or (3) on the branch line.

Using the inventive systems and methods, a user can also specify the length of a particular branch. Moreover, the user can define the angle according to which the branch is connected to the part. Since a user can define the connection from each branch to the part, the user can provide uniform connections. This property has been found to be extremely useful when using tree-shaped supports as inlets for casting silver and gold to create metal structures, such as jewelry. The angle between the branch and the surface of the part influences the influx of material when it is poured into a mold.

Better connections between the branches and the part ultimately reduce the work required for finishing. The finishing is accompanied by a wide range of processes that are carried out by most sectors that produce metal parts. Typically produce produce the finish after a metal part is formed. The finish may consist of any machining or industrial process that changes the surface of a workpiece to obtain a certain property. General metal finishes are accompanied by paint, varnish, ceramic coatings and other surface treatments. Finishing processes can be used to improve appearance, adhesion, wettability, solderability, corrosion resistance, etching resistance, chemical resistance, abrasion resistance, hardness, adjustment of electrical conductivity, removal of burrs and other surface defects, and to control frictional resistance. When all connections are the same and all zones can be treated in the same way, the finish to be performed can be performed more efficiently.

Referring to Figure 5, a block diagram is illustrated with various functional components of an additive manufacturing system 500 suitable for providing improved tree-shaped supports in the production process. The additive manufacturing system 500 can contain various modules that offer 3D printing functionality. In the example illustrated in Figure 5, the 3D production system 500 includes a 3D design module 502. The 3D design module 502 generally takes the form of a collection of computer software and hardware that helps in the creation, adaptation, analysis or optimization of a three-dimensional printed design. The 3D design module 502 can contain computer aided design (CAD) software with 3D design and modeling capabilities.

The 3D production system 500 may also include a 3D data preparation and STL editing module 504. The 3D data preparation and STL editing module 504 typically bridges the design production process. The 3D data preparation and STL editing module 504 can take various forms. In a number of embodiments, it may consist of specialized software configured for running on a special or general computer device. In a number of embodiments, the 3D data preparation and STL editing module can be a software package, for example Magics from Materialize from Leuven (Belgium).

The additive manufacturing system 500 may further include a 3D production and training module 506. The 3D production and training module 506 generally takes the form of a collection of computer software and hardware that controls the forming process of a three-dimensional printed object. In a number of embodiments, the 3D production and training module 506 may be a training processor that is configured for controlling an additive printing device. In other embodiments, the 3D production and training module may include a software solution such as AutoFab from Materialize nv (Leuven, Belgium). The 3D production and training module can be configured with a view to transferring general shape data to an additive manufacturing machine, for example form-ready disk data or, alternatively, STL data, depending on the interface of the machine control software. The machine control software, which may be part of the training module 506 or provided separately, may translate the shape data for the beam checking program for the training process. The additive manufacturing device can then produce the designed product layer after layer in the selected material.

Referring to Figure 6, the 3D data preparation and STL editing module 504 of Figure 5 is shown with more details. The 3D data preparation and STL editing module 504 may include various sub-modules that are configured for performing various functions within the 3D data preparation and STL editing module 504. The 3D data preparation and STL editing module 504 may, for example, include a 3D design input module 601. The 3D design input module can contain various processes and functions, configured with a view to entering data from a CAD system to a three-dimensional printable format such as STL. Although the specific examples in this text are generally directed to STL formatted 3D models, those skilled in the art will appreciate that other 3D print file formats may also be used to implement one or more embodiments described in this text. These formats can be, but are not limited to, 3dmlw (3D Markup Language for Web), ACP (VA Software), VA (Virtual Architecture CAD file), Ashlar-Vellum Argon (3D Modeling), CCM (CopyCAD Model), CATProcess (CATIA V5 Manufacturing document), DWG (AutoCAD and Open Design Alliance applications, Autodesk Inventor Drawing file), EASM (SolidWorks eDrawings assembly file), GLM (KernelCAD model), IPN (Autodesk Inventor Presentation file), PRT - (NX, now known as Unigraphics, Pro / ENGINEER Part, CADKEY Part), SCAD (OpenSCAD 3D part model), SCDOC (SpaceClaim 3D Part / Assembly), SLDASM (SolidWorks Assembly drawing), SLDPRT (SolidWorks 3D part model), TCW (TurboCAD for Windows 2D and 3D drawings), USA (Ashlar-Vellum Vellum Solids).

The 3D data preparation and STL editing module 504 may also include an STL editing and enhancement module 603. The STL editing and enhancement module 603 can be configured with a view to improving a three-dimensional model before additional costs are caused by faulty production. The STL editing and enhancement module 603 may be configured by way of example to allow a user to repair defects such as mirrored triangles, bad edges, holds, etc. The editing and enhancement module may also be configured with a view to enabling a user to improve the design file by adding properties such as hollow parts, logos, etc. Furthermore, a user can also add texture through this module. In addition, and as discussed in what follows with reference to Figure 7, the editing and enhancement module can provide support generation support functionality.

The 3D data preparation and STL editing module 504 may further include a platform generation module 605. The platform generation module 605 can provide functionality that allows a user to prepare the platform for the production process by optimally orienting the parts through nesting and other platform optimization techniques.

Referring to Figure 7, the STL editing and enhancement module 603 is shown in more detail. The STL editing and enhancement module 603 may include a design optimization module 702. As briefly described above, the design optimization module 702 offers the user the opportunity to improve the imported 3D design in various ways. The improvements to the designs can be accompanied by the addition of markings such as product logos, trademarks and serial numbers. In addition, the improvements can be of a structural nature to enable more efficient production. These structural improvements may be the hollowing out of certain parts (to reduce weight and conserve resources), applying texture to a surface, and the like.

As described above, the tree-shaped supports and anchors can be used in the process of additive manufacturing to avoid failures and distortions that occur during the course of three-dimensional printing. To avoid these problems, the editing and enhancement module 603 may include a support generation module 704. The support generation module can take the form of software that is integrated into a multipurpose 3D design software package. Alternatively, it may be a separate module that runs in conjunction with the additive manufacturing system 500.

In a number of embodiments, the support generation module 704 may be configured with a view to providing a user with a graphical user interface that allows the user to easily define different types of anchors and supports. In a number of embodiments, the supports that can be defined may include tree-shaped supports. The tree-shaped supports can generally be used to support objects in various applications of three-dimensional printing. In a number of embodiments, the tree-shaped supports can be used in combination with three-dimensional printing of delicate objects such as, for example, jewelry. These tree-shaped supports can also find a broader application in three-dimensional printing using metal materials and laser sintering processes.

In general, a tree-shaped support defined using the graphic user interface provided by the support generation module 704 may include a trunk and at least one branch. These tree-shaped supports, when printed by means of an additive manufacturing / three-dimensional printing device, can offer numerous advantages. The tree-shaped supports can for instance contain a specific breaking point. The specific breakpoint can make it easier and cleaner to remove the product. The defined tree-shaped supports can also enable a significant reduction in raw material consumption and formation time, while still providing stability. In addition, using specific functionality provided by the support generation module 704 which allows the definition of angular connections between the tree-shaped supports and the object (described in more detail in the following), supports can be removed faster and more easily due to fewer and / or more uniform contact zones on the training platform.

Figures 8-11 illustrate examples of how according to one or more embodiments of the present invention, the support generation module 704 can enable the specification and definition of tree-shaped supports by means of a graphical user interface. With reference to Figure 8, an example of a tree-shaped support 813 in combination with a 3D part design of an object is illustrated. In this specific example, the object is a jewel. The tree-shaped support 813 contains a trunk 801. The trunk 801 is anchored at an anchor point 809. In this example, the anchor point is on the part itself, but those skilled in the art will appreciate that a tree can be anchored by the platform apart from the object. The stem 801 has four branches 803a, 803b, 803c, and 803d. These branches are attached to the top of the stem 807. As illustrated, each of the branches 803 extends from the stem 807 in the direction of the object, where it attaches to a surface of the object at its corresponding anchor point 805. More specifically, branch 803a extends to the surface of the object 811 and connects to junction 805a. Similarly, branch 803b extends to the surface of the object 811 and connects to junction 803b. Branch 803c extends to the surface of the object 811 and connects to connection point 803c, and branch 803d extends to the surface of object 811 and connects to connection point 803d.

In the example of the tree of Figure 8, each of the branches 803 extends from the trunk 807 to its corresponding connecting point 805 via a straight line. As a result, the connection angles of the different connection points 805 are not consistent. However, different connection angles are not conducive to the uniform removal of the tree-shaped supports during the finishing process. In particular, this configuration of the tree-shaped supports can result in an expensive post-processing and finishing.

To address some of the problems associated with the tree-shaped support described with reference to Figure 8, the support generation module 704 can be configured to allow the user to define tree-shaped supports with more control over the configuration of the branches. Figure 9 illustrates a tree-shaped support 900 that can be generated using the support generation module 704. In this example of the tree-shaped support 900, the user can define a perpendicular section of the branch extending from each junction. By defining each branch extending from the connecting point in the perpendicular direction, all connections between the object and the branches of the tree are uniform.

Figure 9 illustrates a tree-shaped support 900 connected to an object 902. In this example, the object 902 is annular. The tree-shaped support 900 contains a trunk portion 904. The top of the trunk portion 904 contains five different branches 908a-908e. Each of the branches 908a-908e can be defined by the user to extend perpendicularly from the surface of the object to which it is connected. As illustrated, each of the branches 908a-908e initially extends outward from a junction 912a-912e on a surface of the object 902. Each of the branches extends perpendicularly from the surface to which it is attached connected. After a short distance, the direction of each branch changes according to an angle 910a-910e leading each branch to the top portion of the stem 904.

Referring to Figure 10, a graphical user interface 1000 of the support generation module 704 is illustrated. This graphical user interface 1000 can be used to enable a user to define various aspects of a tree-shaped support. In this example, the user has defined the tree interface element 1001 that extends to a trunk element and a branch element. The root element was selected. As a result, a trunk definition zone 1003 is displayed. Through this screen a user can define the attributes of the trunk of a tree. The user can get a visual representation of the trunk 1011 that is being defined, with various menu options that define root parameters of the tree-shaped support. In this specific example, the user can define the diameter of the top 1013 of the stem 1011 with the diameter top (d1) input field 1005. A user can also define the diameter of the bottom 1017 of the stem 1011 with the diameter bottom (d2) ) input field 1007. The user can also define the height 1015 of the trunk 1011 with the height (h) input field 1009. Thus, the user is offered a detailed check of the shape and size of the trunk portion of a defined tree-shaped support.

Figures 11A-11D give an example of a graphical user interface that can be provided by the support generation module 704 to allow a user to define properties of the branches in the tree-shaped support. Figure 11A illustrates an exemplary configuration of an elemental branch, such as branches 803a-803d described with reference to Figure 8 above. As illustrated, the user has selected branch option 1100 from the navigation menu for the support parameters. As a result of this selection, the support generation module has defined a graphical user interface 1102 with which a user can define the properties of one or more tree-shaped supports. In this specific screen, the user can define branch parameters 1104 of the tree-shaped support. For example, the diameter of the top 1124 of a selected branch 1132 can define with the diameter top (d1) input field 1106. The diameter of the bottom 1130 of a selected branch 1132 can be defined with the diameter bottom (d2) input field 1108. In the example of Figure 11A, the user has chosen not to include break points. As a result, the "add break-off point" box has remained empty. The other fields for defining a breakpoint are grayed out so that the user does not have to enter any values. As described above, the properties selected in Figure 11A would lead to an elemental tree branch such as the branches 803a-803d in Figure 8.

With reference to Figure 11B, an example is given of a graphical user interface environment 102 in which a breakpoint 1134 is defined. The break point is defined by the user's selection of the add break-off point check box 1110. Once the user has indicated that the tree branch must contain a break point, the other properties of the break point are no longer gray. The diameter of the interruption point 1128 can then be defined in the diameter (d3) input field 1112. The distance from the connection surface 1122 of the part 1120 to the interruption point 1134 can also be specified by the distance from the top (x) - input field 1114. Similarly, a breakpoint location 1116 can be defined by selecting various options proposed to the user. In the example of Figure 11B, the normal triangle option 1118 was selected. This option defines the angle between the connection surface 1122 and the directional length "x" 1126 of the branch as perpendicular or 90 degrees. By making the selection as illustrated in Figure 11B, the user can easily define one or more of the branches of the tree as having a uniform connection to the surface of the object.

Referring to Figure 11C, the graphical user interface environment of Figure 11A is illustrated. In this case, the user has not selected the "triangle normal" option for the interruption point location. Instead, he opted for the "on branch line" option 1118. As a result, the support generation module creates a linear connection from the trunk (positioned on the lower diameter 1130) to the surface of the object 1120. Figure 11D illustrates yet another optional variation of the branch configuration. In this example, the user has selected the "vertical" option 1118. The vertical option specifies that the branch should be vertical at the interruption point as represented by the right angle 1130 defined in the horizontal platform with the dashed line extending perpendicularly (and vertically) to the connection point 1124. Consequently, as illustrated in the Figures 11A-11D, the support generation module 704 are configured to provide the user with a high degree of flexibility in defining the structure and connection properties of tree-shaped supports.

In a number of embodiments, systems and modules as described above can be configured with a view to carrying out a method for optimizing contact points for tree-shaped supports. Referring now to Figure 12, a high-level illustration of such a process is shown. In a number of embodiments, the process can be performed by a support generation module 704. As another possibility and depending on the specific implementation environment, the process can be performed by any other module in an additive manufacturing system. For example, the process can be performed on an application server that is accessed by a client application (such as an application running through a web browser) to obtain data input and perform contact point optimization operations based on data received through a computer network.

The process starts at block 1202, where the three-dimensional design is analyzed to determine which supports may be needed to successfully perform the shaping without disturbances or distortions of the object. This can be achieved in various ways. In a number of embodiments, a specific self-supporting angle can be used to determine which surfaces of the three-dimensional object require support generation. This angle can be set as standard by the support generation module 704, or can be adjusted by the user. Depending on the physical properties of the materials used and the applied additive manufacturing process, the self-supporting angle can be in the range of 30-45 degrees. In certain scenarios, the self-supporting angle may also be outside that range. When an overhang of the three-dimensional design is at the self-supporting angle, a tree-shaped support can be assigned to that part of the design. Alternatively, the supports can be manually defined by the user and entered through the graphical user interface provided by the support generation module 704.

Once the necessary tree-shaped supports have been determined, the process continues to block 1204. There, the trunk of a tree-shaped support can be defined. The parameters can be automatically selected by the system or can be specified and entered by the user. As described above with reference to Figure 10, the parameters of the stem may include various measurements such as the diameter of the top, the diameter of the bottom, and / or the height of the stem.

Then the process may proceed to block 1206 where the tree-shaped support is anchored. The trunk can be anchored to the forming platform on which the object is produced, or to another tree-shaped support. In a number of embodiments, the anchor can be selected automatically. However, the user may be offered the option of changing the selected anchor by means of a graphical user interface provided by the support generation module 704. The process then continues to block 1208. There, the specific connection points that connect the tree to the object can be specified. In a number of embodiments, these connection points can be identified and selected by the user through a graphical user interface provided by the support generation module 704. A branch of the tree can be defined for each connection point.

Once the connection points have been identified, the process continues to block 1210. There, the connection types for each connection point identified in block 1208 are determined and / or selected by the user. The process then proceeds to block 1212, where the branches are connected to the surface of the part and the connection points and also connected to the trunk to create the tree-shaped support. The process then continues to block 1214, where the object is printed three-dimensionally with the tree-shaped supports and any finishing operations are performed to produce a final device produced.

Figure 13 is a more detailed flow chart of the selection of connection types and parameters as illustrated in block 1210 of Figure 12. The process starts at block 1302, where the diameters of each branch of the tree are defined. In a number of embodiments, the diameters are defined by the user through a graphical user interface provided by the support generation module 704. The process then proceeds to decision block 1304, where it is determined whether the branch will contain a break point (such as, for example, the break points as illustrated in Figures 11B-11D). If no branch tree breakpoint is required, the process continues to block 1306, where the corner of the junction is confirmed as a straight line between the junction and the top of the trunk.

Returning to block 1304, if a breakpoint is required, the process proceeds instead to block 1308. There, the user can choose a breakpoint location. As described above with reference to Figs. 11B-11D, the support generation module may provide predefined breakpoint locations such as on the branch line, normal triangle (extending perpendicularly from the object surface), vertically or any other location and / or connection angle. Then the process continues to block 1310 where relevant measurements can be defined. These measurements can include the distance to the object where the breakpoint is located on the branch. These measurements may also include the diameter of the break-off point or any other measurements that affect the physical properties of the tree-shaped support and allow for easy removal.

Embodiments of the present invention provide various solutions for configuring branches in tree-shaped supports. These different configurations offer advantages such as uniform connections between tree-shaped supports and parts that allow for more efficient removal in the course of the finishing process. Moreover, the user gets more flexibility in determining and choosing the angle according to which a tree-shaped support is connected to an object. The increased control may offer the possibility of using the tree-shaped supports for purposes other than simply supporting the object during the forming process. For example, tree-shaped supports can be defined that are used as inlets for pouring liquid metal into a three-dimensional printed mold. The angle that the branch makes when connecting to the surface of the part can be used to control the flow of the material when it is injected into the mold.

The invention described in this text can be implemented in the form of a method, a device, a produced article, using standard techniques of programming or engineering to produce software, firmware, hardware or any combination thereof. The term "produced article" as used herein refers to code or logic implemented in hardware or permanent computer readable media such as optical disks, and volatile or non-volatile memory devices or temporary computer readable media such as signals, carriers, etc. Such hardware may include, but is not limited to, FPGAs, ASICs, complex programmable logic devices (complex programmable logic devices, CPLDs), programmable logic arrays (programmable logic arrays, PLAs), microprocessors, or other similar processing devices .

It should be understood that any feature with respect to any embodiment may be used alone or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. In addition, equivalents and modifications not previously described can also be implemented without departing from the scope of the invention which is defined in the appended claims. in the drawings:

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Claims (10)

CONCLUSIONS A method for performing a method for optimizing contact points for tree-shaped supports in an additive manufacturing environment, the method comprising: - analyzing the object to determine required supports; - defining the trunk for a tree-shaped support; - anchoring the trunk of the tree-shaped support to a platform; - determining connection points for at least one branch of the tree-shaped support on the object; - selecting connection types and parameters for branch connections on the surface of the object; and - connecting at least one branch to the sub-surface and the trunk of the tree to create the tree-shaped support. The method according to claim 1, further comprising the production and finishing of the object in an additive manufacturing environment. The method of claim 1, wherein selecting connection types and parameters is associated with defining branch diameters for the at least one branch. The method of claim 3, wherein selecting connection types and parameters is further accompanied by: - determining whether the at least one branch will contain a break point; and - selecting a breakpoint location if the at least one branch will contain a breakpoint. The method of claim 4, wherein the method further comprises defining breakpoint measurements. 6. A system for optimizing contact points for tree-shaped supports in an additive manufacturing environment, the system comprising a processor configured to execute computer instructions that: - analyze an object to determine required supports; - define a trunk for a tree-shaped support; - anchoring the trunk of the tree-shaped support to a platform; - determine connection points for at least one branch of the tree-shaped support on the object; - select connection types and parameters for branch connections on the surface of the object; and - connecting the at least one branch to the sub-surface and the trunk of the tree to create the tree-shaped support. The system of claim 6, wherein the processor is further configured to execute instructions that cause an additive manufacturing device to produce and process the object in the additive manufacturing environment. The system of claim 6, wherein the processor is further configured for the purpose of executing instructions that select connection types and parameters by defining branch diameters for the at least one branch. The system of claim 8, wherein the processor is further configured to execute instructions that select connection types and parameters by: - determining whether the at least one branch will contain a breakpoint; and - selecting a breakpoint location if the at least one branch will contain a breakpoint. The system of claim 9, wherein the processor is further configured to execute instructions that select connection types and parameters by defining breakpoint measurements.