GB2542552A

GB2542552A - Methods, systems and apparatus for construction of three-dimensional objects

Info

Publication number: GB2542552A
Application number: GB1515360.4A
Authority: GB
Inventors: Baraja Guillermo; Nadal Adolfo
Original assignee: Naotech Solutions S L
Current assignee: Naotech Solutions S L
Priority date: 2015-08-11
Filing date: 2015-08-28
Publication date: 2017-03-29
Also published as: GB201515360D0

Abstract

A geometry core could be related to the particular 3D platform used to design the object, e.g. the particular file type used by AUTOCAD. Or it could be related to the core geometry of the computer designed shape. The method disclosed provides a design of a three-dimensional object to be generated; determining the geometry core used to design the three-dimensional object; converting/translating the geometry into a number of targets based on the determined geometry core; determining a toolpath for a multi-axis robot having an extruder head with material for generating the three-dimensional object based on the targets; calculating the motion required such that the multi-axis robot follows the toolpath; and executing the motion of the multi-axis robot (350) to generate the three-dimensional object according to the design. Accordingly, the versatility of the multi-axis robot is increased. The method is used to ensure that different design files can be translated into robot readable files (e.g. printing files). An extruder is also disclosed which has a polygonal nozzle, comprising a plurality of interconnect blades that lock in a first position to close the orifice or splay in a second position to open orifice.

Description

METHODS, SYSTEMS AND APPARATUS FOR CONSTRUCTION OF THREE-DIMENSIONAL OBJECTS

Field

The present disclosure relates to a method of generating three dimensional objects. In particular it relates to a method of generating three-dimensional objects from a material using a multi-axis robot. An extruder is also disclosed.

Background

Current 3d printing processes mostly focus on small-scale parts and rapid prototyping. SLS (Selective Laser Sintering) and FDM (Fused Deposition Modelling) techniques have a layer-by-layer approach to 3d printing, which presents a number of limitations. For instance, plastic extrusion creates support parts that need to be manually removed and further refined.

On the other hand, oversized approaches to 3D printing intend to replicate small scale machines by simply scaling them up, resulting in either lots of material waste (D-Shape printer) or techniques similar to Contour Crafting, which again require material continuity in order to work. This means that the production of holes in walls, for instance, is not possible. Furthermore, these machines require heavy industrialization and workspace, making it difficult for them to be deployed on site. In addition to that, these techniques are rough and do not manage to yield fine results, they lack precision and have too large error values.

There are many examples that make use of these particular technologies. Some of them are the D-Shape 3D printer Radiolaria Project (which basically consists of a scaled-up version of a Z-Corp printer), the WinSun new materials Singapur Home, and many others. Both examples fail at various points: the most prominent problem of the Radiolaria Project is the amount of material that is required for the fabrication, along with the size of the infrastructure, which makes it unsuitable for hard sites. The WinSun 3D modules, on the other hand, need to provide more complex solutions that incorporate building systems, structural elements, and finish into the final products.

Previous efforts have been made to try to facilitate the use of desktop three-dimensional printers in the marketplace. However, due to the relative dispersion of the market, one consequence of its relative youth, no combined effort exists that unites production processes and the design workflows into a simple easy to follow procedure. This particularly makes existing solutions difficult to use for non-specialist users. Difficulties include ensuring feasible and technologically viable three-dimensional designs, the many different software packages used to generate designs, which must then be translated into robot readable files, and accounting for errors that may arise during the production process.

Whilst some solutions exist for translating pre-existing design packages from multiple sources into a single visualisation software, there is no existing solution that applies such thinking to the whole manufacturing process from design to construction. In other words, whilst programs exist which allow inputs of designs having different geometry cores (e.g. different geometry kernels) so that the design can be visualised in a single program independent of the programme used to generate the design, providing command robot software based on such visualisations has not been realised.

Summary

According to a 1st aspect of the present disclosure there is provided a method of generating three dimensional objects from a material using a multi-axis robot; said method comprising the steps of: providing a design of a three-dimensional object to be generated, the design having geometry based on a geometry core; determining the geometry core used to design the three-dimensional object; converting the geometry into a number of targets based on the determined geometry core; determining a toolpath for a multi-axis robot having an extruder head with material for generating the three-dimensional object based on the targets; calculating the motion required such that the multi-axis robot follows the toolpath; and executing the motion of the multi-axis robot to generate the three-dimensional object according to the design.

In embodiments, the step of determining the geometry core used to design the three-dimensional object may further comprise the steps of: querying a database of geometry cores; and assigning the geometry core that matches the design.

Preferably, the step of determining a tool path may comprise the step of: mapping the targets onto a planar surface.

The step of calculating the motion required may further comprise the step of: translating the targets into movement instructions. In such embodiments, the method may further comprise the steps of: identifying a robot language of the multi-axis robot; and providing the movement instructions in the robot language to the multi-axis robot. Furthermore, the movement instructions may be exported in the robot language.

In embodiments, the step of calculating the motion required may further comprise the steps of: identifying the material for generating the three-dimensional object using the extruder head; and altering the motion required based on properties of the material.

The method may include the step of simulating movement of the motion of the multi-axis robot prior to execution. The method may also include the step of selecting the model of multi-axis robot from a database of known multi-axis robots. Alternatively or additionally, the method may comprise the step of selecting the model of the multiaxis robot according to the size of the model desired to produce the end product. A track motion assistant may also be used to allow robot movements in static axes (7, 8 and 9 axes). Such assistant units allow bigger models to be produced due to the ability of the robot to move around the model. Accordingly, such track motion assistants are useful when the model is bigger than the stationery range of the robot.

The axis of rotation for the toolpath may be determined based on existing physical elements to prevent collision between the multi-axis robot and the physical elements. A production time estimate for generating the three-dimensional object based on the material used and the multi-axis robot may also be provided.

In embodiments, the material may be a biomaterial or composite thereof. Additionally or alternatively, the material may be a biodegradable plastic or composite thereof.

The step of providing a design may further comprise the step of: supplying or selecting a design of the required three-dimensional object to be generated from a database of designs of the required three-dimensional object, wherein the geometry core originally used to produce the design selected from the database of designs is known; and wherein the step of determining the geometry core comprises the step of identifying the geometry core from the database of designs.

In one embodiment, the step of providing a design further comprises the step of: supplying or selecting a design of the required three-dimensional object to be generated from a database of designs of the required three-dimensional object, where in the geometry core originally used to produce the design selected from the database of designs is not known and wherein the step of determining the geometry core comprises the step of testing the design of the three-dimensional object to be generated using known geometry cores to identify the geometry core used for the design.

According to a 2nd aspect of the present disclosure, there is provided an interface for undertaking the method of any embodiments of the 1st aspect, wherein the interface is provided with one or more selection options chosen from: a material selector for identifying the material used to generate the three-dimensional object; a contour selector for selecting the thickness of material required to generate the three-dimensional object; a robot model selector to identify a multi-axis robot used to generate the three-dimensional object; a simulation display for viewing a simulation of the motion along the tool path prior to generation of the three-dimensional object; a timer for estimating the time necessary for generating the three-dimensional object; and a material indicator for indicating the material used by and/or the material left in the extruder.

According to a 3rd aspect of the present disclosure, there is provided a system for generating three-dimensional objects from material using a multi-axis robot, said system comprising: an interface for translating a design of a three-dimensional object from a geometry core used to describe the design into a series of targets; a multi-axis robot with an extruder for extruding material to generate the three dimensional object; and a kinematic engine for placing the robot on a toolpath based on the targets.

In embodiments, the extruder may be configured to automatically vary the opening and closing of a nozzle to control their position and the extrusion of the material along the toolpath.

Furthermore, the extruder may comprise one or more adjustable blades configured within the extruder for composing a circle through which the material is extruded.

In embodiments, a remote interface for controlling the multiaxis robot and/or housing the interface is provided. The remote interface may be a remote control unit, a smartphone application, a laptop or computer application or any such interface device provided remotely to the robot.

According to a 4th aspect of the present disclosure, there is provided a multiaxis robot with an arm having an extruder for extruding material to generate a three-dimensional object, the robot comprising: an interface for undertaking the method of any embodiment of the 1st aspect or an interface according to the 2nd aspect; motors for controlling the movement of the arm in at least 6 axial directions; a supply of material provided to the extruder for generating the three-dimensional object; and a nozzle through which the material is extruded and wherein the nozzle is opened and closed using a set of adjustable blades.

According to a 5th aspect of the present disclosure, there is provided a computer program product for facilitating generation of a three dimensional object, the computer program product comprising a non-transitory computer-readable medium including codes for causing the computer to perform the method of any embodiment of the 1st aspect.

Additive digital fabrication techniques such as those described above provide the advantage of the optimisation in the use of materials. This can be relevant when producing large amounts of small parts, and is additionally relevant when dealing with large scale construction techniques. Waste management and access of construction materials are issues that must be managed during construction projects and using future construction techniques. In current construction sites, waste constitutes a large proportion of construction costs. Green certifications typically seek, amongst other issues, to solve the problem of waste management by using local materials and thus minimise transportation costs.

Advantages of large-scale 3-D printed parts (or even entire buildings) are that they have preprogrammed and precalculated material costs and estimates, which are determined by the geometry of the elements themselves. By manufacturing using extrusion techniques, the risk of failure is minimised. Automation and mechanisation of the process also minimises human errors and other mistakes which accounts for the majority of the defects in housing construction.

Use of free printing is a possible solution for providing zero waste management and optimised on-site waste management. This can also be extended throughout the life cycle of the building. Other benefits include maximised profit through optimised material use, minimise construction times and volumes (only construct what is needed), maximise safety by reducing labour involvement on-site, minimised operation costs, upscaling of workers and labour force, higher quality finish of products and construction and implementation of next constructive elements including undifferentiated structural elements and building systems.

Biomaterials may also be used, which typically have a reduced energy footprint. Most manufactured materials have a large amount of embedded energy which makes them difficult to manufacture and transform initially and also makes them difficult to recycle once at their life cycle is over. Conversely, organic materials can be more easily obtained from their raw material counterparts. They typically require less embedded energy and provide long-lasting qualities and possible recycling opportunities. One example is PLA (polylactic acid), which is used in the aerospace industry. PLA is a biodegradable plastic that can be derived from renewable resources such as cornstarch, tapioca routes and other plants from the world. Similar materials (or composites including this bioplastic or other mixtures) may also be employed for different industries depending on characteristics of materials required.

Further examples of such materials are carbon fibre or polyamides materials and their composites, such as with PLA. Such composites maybe be used for car trims or for nonstructural panels thanks to their light weight and high quality finish. Bio cements with natural fibres may also be particularly suitable for the construction industry. In addition to being renewable and recyclable, such materials are also reusable on-site of the construction. Conversely, current construction materials typically restrict the use due to the way they are manufactured. Reusable materials may be reused in place in case of execution defects.

The extruder may be adapted to the requirements of material. The extruder may be an industrial extruder. In such examples, the material may be presented for this use.

Material may be deposited in 6 + 3 axes as characterised by the necessary efficient extrusion and construction of the material. A high mechanical strength may be provided at a minimum weight and minimum energy consumption costs.

Material may be deposited at any point in space with a total freedom of movement without limitations using such a multiaxis robotic arm. Continuous and discontinuous deposition or extrusion is possible.

The multiaxis robotic arm may be provided on a shaft to allow extrusion outside of the natural range of motion of the robotic arm.

The system and/or the robot may be deployed on site to allow the use of local energy sources and resources. This may include renewable sources of energy such as wind, solar, etc.. Such renewable energy sources may be provided as part of the system. The energy may be used to feed the motors of the robot, the supply of material, or even the extruder or tool.

According to a sixth aspect of the present disclosure there is provided an extruder for directing extrusion material using a multi axis robot, said extruder comprising: a polygonal nozzle, said polygonal nozzle comprising a plurality of interconnected blades that interlock in a 1st position to provide a closed orifice for the nozzle and splay open in a 2nd position to provide an open orifice for the nozzle.

In embodiments, the interconnected blades may form exterior walls of the nozzle. In related embodiments the nozzle may be considered frustoconical in shape in the 1st position. Additionally or alternatively, the nozzle is substantially cylindrical in the 2nd position.

The blades may comprise fins that are exposed when the blades splay apart. The use of fins ensures that the orifice of the nozzle is continuous in the open position.

The extruder may further comprise a ring external to the nozzle and coupled to the blades, wherein the lateral position of the ring relative to the nozzle determines the degree of splaying of the blades in the 2nd position. This allows fine control over the degree of opening of the orifice and therefore the nozzle. This provides a high degree of control when metering material through the nozzle.

It can be appreciated that for any of the above described embodiments and aspects, the motion may be axis rotation. The axis rotation may be about one or more of the axes of the multi-axis robot. Lateral movement may also be envisaged as described above.

These and other aspects of the invention will be apparent from, and elucidated with reference to, the embodiments described hereinafter.

Brief description of Drawings

Embodiments will be described, by way of example only, with reference to the drawings, in which figure 1A illustrates an overview of current interactions between designers and their designs; figure 1B illustrates the proposed interactions between designers and their designs according to aspects of the present disclosure; figure 2 outlines the proposed method workflow of figure 1B; figure 3 shows a remote access variant of the system shown in figure 1B; figure 4A - F illustrates the method workflow of figure 2; figure 5 shows an interface for controlling and undertaking the method illustrated in figure 4; figure 6 shows an extruder with a nozzle according to an embodiment of an aspect of the present disclosure; figure 7A and 7B show open and closed configurations of the nozzle of figure 6; and figures 8A and 8B show blades that comprise the nozzle of figures 7A and 7B.

It should be noted that the Figures are diagrammatic and not drawn to scale. Relative dimensions and proportions of parts of these Figures have been shown exaggerated or reduced in size, for the sake of clarity and convenience in the drawings. The same reference signs are generally used to refer to corresponding or similar feature in modified and different embodiments.

Detailed description of embodiments

According to one aspect of the present disclosure, an integrated workflow is presented that integrates the 3 main aspects of design into a single, easy-to-use package. The workflow takes existing 3-D modelling platforms, provides machine interaction and set up, and enables fabrication and physical interaction.

An overview of existing interactions between designers, their design and the fabrication of the design is shown in figure 1 A. In this example, the design and its designer undertake several iterative stages perfecting the design, before the designer supplies the design to a fabrication team. The designer maintains user involvement (typically undesirable) during the fabrication process. Conversely, in the proposed disclosure shown in Figure 1B, the interaction between the designer, their design and the fabrication team is altered. In the proposed workflow, alterations in the design are fed through to the fabrication team, with the input of the designer (if desired).

The proposed workflow is shown in figure 2. In this example, architecture, engineering and construction software 200, which typically comprises design software 210 having geometry cores 212 and modelling software 220 having geometry cores 222 are provided to a translator module 230 comprises a series of translators 232 that are configured to read design files and design models 234 output by the design software 210 and modelling software 220. Similarly, for industrial design software 240, industrial designs having geometry cores 242 produced by such software are provided to a translator 244. It can be appreciated that the number of translators 232, 244 can be equal to the number of design software, modelling software and industrial design software geometry cores able to be read by the translator module 230. The translators 232, 244 are configured to translate the designs received from the software and to generate robot software 250 that may then be provided to a fabrication module 260.

By reading the geometry cores 212, 222, 242, the translator module 230 is able to decode the designs output by the design, modelling and industrial design softwares and can select the correct robot software 254 the design based on the geometry core used to create the design. The translator module is able to feedback changes made to the design and also allows a visualisation of the design prior to construction.

This workflow permits users to double check their designs in real time, allowing users to minimise or eliminate floors during execution of the designs during fabrication. User interactivity and information flow can be increased due to this overall standardisation process. In other words, instead of requiring that each design has a particular geometry core to be individually decoded, and robot software generated to recreate the design according to the selected geometry core, the present disclosure and workflow allows a user to provide a design which is read in an automated manner, with the geometry core used to generate the design detected automatically and the design converted into robot software for construction of the design.

Additionally, the workflow is able to list the possible flaws and their cause during the design time, prior to construction, so that the user can correct them and can decide how to continue with the design.

Additionally, a crucial element in any digital fabrication process is to include cost prediction. The real-time simulation of the fabrication process by the present workflow includes material usage, time needs and the total manufacturing costs. These initial estimates are available due to the overall simulation process which, having already involved costly geometric calculations, provide material and time yields and accounts for the above estimates to provide on-site predictions.

As can be seen in figures 1B and 2, the user’s involvement in the overall design realisation process can be shown to decrease gradually from design to production. This allows a designer or prototype manufacturer to focus on creating a design that matches their expectations without having to manage the fabrication process.

Providing a central external core the runs the geometry calculation and translation operations together with translators for different pre-existing design packages, each having their own design geometry core, results in a highly modular, cross-platform and extendable software that anyone can use. This facilitates the modularity and expandability of the whole integrated process as shown in figure 2.

Figure 3 shows a remote access variant of the system shown in figure 1B. Figure 3 shows how a designer 310 may use a remote interface 320 to interact with design software 330 connected to a plug-in 340 and a robot 350. The plug-in 340 may be the translator module 230 shown in figure 2 configured to provide robot instructions 250 to the robot 350. The robot may be a 3-D printer or it may be a multi axis robot with an extruder head able to exclude material to construct the design generated by the designer 310 via the design software 330 and the plug-in 340.

The remote interface 320 may be a handheld device, such as a remote control, or an application for the mobile software device such as a phone or tablet. The remote interface 320 provides two-way communication between the design software 330 (via the plug-in 340) and can provide a simple visual interface to control the design process in real time during the fabrication by the robot 350.

Workflow described in figure 2 requires a complete integrated interaction between software (the design software 210, 220, 230) and hardware such as the robot 350. This is achieved by creating small translator software modules 212, 222, 242 that deal with the translation of different geometry types or geometry cores, which are a consequence of the different software packages available, in order to translate the designs created by such geometry types or cores into robot movement through the description of targets and tool paths.

In order to determine the characteristics of the design submitted or provided, the software includes a geometry calculation core and a translation core which communicate with the design software package with or without a plug-in translator core. The plug-in is capable of taking care of the calculation of tool paths, digital inputs and outputs and that describing the tool path. In addition, the plug-in performs automatic error detection as will be described below. In addition, the plug-in creates the necessary files and protocols required for physically moving the robot 350.

Examples of CAD software having packages suitable for consideration are rhinoceros, revit and AutoCAD. These packages are linked to the construction industry. These packages typically offer a number of well documented advantages, such as being a generic platform for all main target industries (automotive, aerospace and construction sectors), they provide a very powerful geometry core which may be open for third-party developers and they provide an intuitive 3-D interface.

According to the present disclosure, a software or hardware plug-in assesses the geometry core of the software platform and converts the geometry of the design submitted into a series of targets. These targets represent the actual 3-D positions of the tool along a plane, which in turn, when linked, constitute a tool path. Then, an inverse kinematics engine places the robot along the tool path according to motion calculations and the actual physical dimensions and possible movements of the selected robot model. This is processed automatically by the processor of the plug-in. An interface may be provided as described above that is seamlessly integrated with the selected 3-D platform (i.e. geometry core). Native panel programming is provided to achieve this which provides high-quality displays of information. Information displayed may include the following elements: a material selector for automatic robot presets; a contoured definition for determining and providing different material thicknesses; a robot model selector to allow selection of the type of robot from a list of implementable models or additional models loaded by the user; simulation display to play, stop and resume robot movement simulation (also allowing the user to zoom in to the design to see detail for coarse levels); clash detection calculations to prevent the robot from colliding against physical elements; error detection for highlighting out of range calculation is an error is within the modelling and design; an estimate of the time of production and the time to finish the design; and material control to highlight the material used and the material available for use. Providing these options allow the plug-in core to calculate the necessary information to create the tool path for the robot.

The plug-in translates the geometry of the design (the tool paths defining the positions and a series of digital inputs and outputs) into movement instructions for the robot 350. For commercial robots, this generally means curved or linear movements that must be described in the robot language. For example ABB robots use RAPID, Kuka robots use KUKA, etc.. These files must be uploaded to the robot and executed with in the robot’s own protocols internally. This results in actual robot operations.

Figure 4A shows a design 410 of a three dimensional object to be generated. The design is typically based on a core geometry as noted above. The design is provided to the translator module 230 to determine the core geometry 420 used to design the three-dimensional object as shown in Figure 4B. The translators 230 then act to convert the geometry 420 into a number of targets 430 based on the determined geometry core as shown in Figure 4C. A planar surface 440 is then defined against which the design can be realised (figure 4D). Based on the planar surface and the targets, the robot software 250 then determines a toolpath 450 for a multi-axis robot 350 having an extruder head 600 with material for generating the three-dimensional object based on the targets 430 as shown in Figure 4E. The motion required such that the multiaxis robot 250 follows the toolpath 450 can then be calculated such that the robot 350 follows the toolpath 450 as shown in Figure 4F. Once calculated, the multi-axis robot executes the motion required to generate the three-dimensional object 460 according to the design (figure 4G).

An example of the interface of the system is shown in figure 5. In figure 5, a screen 500 is shown. The interface 510 provides a means for the user to control the methods and system described above. The screen provides a representation of the toolpath 450 of the proposed design 410 or object 460 as described with relation to figure 4. Physical objects of the surroundings may also be shown. A number of inputs and selectable options 520 are provided which allow the user to select alternative inputs as described above. In particular, the height, thickness or mesh size of the toolpath may be selected. Toolpaths may be generated or reset. Robots used for the production of the object 460 may be selected by company and model number. Previews may be generated, with the level of coarse and fine detail selectable. The geometry output, such as mesh, may also be selected. Further scripts for the robot, collision detection to avoid physical objects and the time taken for the build can all be selected and controlled where appropriate.

Typically, the robot 350 has an extruder 600 for supplying material for construction via injection or extrusion. The extruder is shown in Figure 6 and may be provided in a single unified piece with a nozzle 610, block heater, screw and sink. This allows faster temperature range printing. A PTFE tube is generally included to reduce the friction of the exclusion filament, along with a cap that seals the top to avoid leakage. Electro treatment may also improve the passage of material through the filament. Ceramic, clay or concrete may be provided as the material from exclusion through the extruder. In this case, the materials are provided as a paste and are pushed through a Bowden style tube into a nozzle 610. A piston, typically driven by a stepper motor, is used to push the paste through the nozzle 610.

The extruder 600 is provided with a series of holes 620 through which a step motor can be provided. The holes 620 are configured to accept a bolted shaft 630 that is driven by the step motor. A ring 640 is threaded onto the bolted shafts 630 and regulates the size of an aperture or orifice 650 of the nozzle 610. Finally, a nozzle shaft holder 660 is provided to accommodate a series of blades 810 as will be further described below.

The nozzle is configured to have an open position 710, where material is able to freely flow through the orifice 650 of the nozzle 610 and a closed position 720 where the diameter of the orifice 650 is reduced and material is constricted from flowing through the nozzle 610. In the example shown, the nozzle is configured to splay open from the closed position 720 to the open position 710. The size of the orifice 650, i.e. the amount of opening is controlled by the position of the ring 640 along the bolted shafts 630. As shown, the nozzle 610 is generally polygonal in shape and forms a frustoconical shape when in the closed position 720 and a substantially cylindrical shape when in the fully open position 710.

As described above, the extruder 600 is designed to automatically vary the opening and closing of the nozzle in order to make a more controlled and optimal deposition pattern depending on the extruder model. One example of how the nozzle is opened and closed is to use a set of adjustable blades 810 to compose a circle through which the material is injected. These blades 810 are shown in figures 8a and 8b.

Figure 8A shows a top view of the blades 810. A single blade 810 is shown, however multiple blades may be arranged around a centre axis and within a nozzle (not shown) of an extruder. Each blade 810 is provided with a circular aperture 820 for receiving the nozzle shaft 660 located at the periphery of the nozzle. The blade 810 typically has two flat surfaces 812 that taper from a larger width at the circular aperture end 822 towards a tip 830. Each flat surface is arranged at approximately an 18° angle to the other flat surface 812. The position and angle of blades relative to the flow of material through the nozzle of the extruder can be varied to alter or stop the flow of extrusion through the nozzle.

Multiple blades 810 interlock as shown in Figures 6 and 7. The blades 810 also have fins 840 that emerge from within the blades 810 as the blades are splayed relative to each other. The fins 840 act to allow the orifice 650 to expand as the nozzle opens, maintaining a continuous orifice 650.

From reading the present disclosure, other variations and modifications will be apparent to the skilled person. Such variations and modifications may involve equivalent and other features which are already known in the art of design realisation and extrusion and which may be used instead of, or in addition to, features already described herein.

Although the appended claims are directed to particular combinations of features, it should be understood that the scope of the disclosure of the present invention also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalisation thereof, whether or not it relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as does the present invention.

Features which are described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. The applicant hereby gives notice that new claims may be formulated to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom.

For the sake of completeness it is also stated that the term "comprising" does not exclude other elements or steps, the term "a" or "an" does not exclude a plurality, and reference signs in the claims shall not be construed as limiting the scope of the claims.

Claims

1. A method of generating three dimensional objects from a material using a multi-axis robot; said method comprising the steps of: providing a design of a three-dimensional object to be generated, the design having geometry based on a geometry core; determining the geometry core used to design the three-dimensional object; converting the geometry into a number of targets based on the determined geometry core; determining a toolpath for a multi-axis robot having an extruder head with material for generating the three-dimensional object based on the targets; calculating the motion required such that the multi-axis robot follows the toolpath; and executing the motion of the multi-axis robot to generate the three-dimensional object according to the design.

2. A method as claimed in claim 1, wherein the step of determining the geometry core used to design the three-dimensional object further comprises the steps of: querying a database of geometry cores; and assigning the geometry core that matches the design.

3. A method as claimed in claim 1 or 2, wherein the step of determining a tool path comprises the step of: mapping the targets onto a planar surface.

4. The method as claimed in any preceding claim, wherein the step of calculating the motion required further comprises the step of: translating the targets into movement instructions.

5. The method as claimed in claim 4, further comprising the step of: identifying a robot language of the multi-axis robot; and providing the movement instructions in the robot language to the multi-axis robot.

6. The method as claimed in claim 5, further comprising the step of exporting the movement instructions in the robot language.

7. The method as claimed in any preceding claim, wherein the step of calculating the motion required further comprises the steps of: identifying the material for generating the three-dimensional object using the extruder head; and altering the motion required based on properties of the material.

8. The method as claimed in any preceding claim, further comprising the step of simulating movement of the motion of the multi-axis robot prior to execution.

9. The method as claimed in any preceding claim, further comprising the step of selecting the model of multi-axis robot from a database of known multi-axis robots.

10. Method as claimed in claim 9, wherein the step of selecting the model of multi-axis robot further comprises the step of providing a track motion assistant to allow robot movements relative to the object to increase the range of the multiaxis robot.

11. The method as claimed in any preceding claim, wherein the motion for the toolpath is determined based on existing physical elements to prevent collision between the multi-axis robot and the physical elements.

12. The method as claimed in any preceding claim, further comprising the step of estimating a production time for generation of the three-dimensional object based on the material used and the multi-axis robot.

13. The method as claimed in any preceding claim, wherein the material is a biomaterial or composite thereof.

14. The method as claimed in any preceding claim, wherein the material is a biodegradable plastic or composite thereof.

15. The method as claimed in any preceding claim, when the step of providing a design further comprises the step of: supplying or selecting a design of the required three-dimensional object to be generated from a database of designs of the required three-dimensional object, wherein the geometry core originally used to produce the design selected from the database of designs is known; and wherein the step of determining the geometry core comprises the step of identifying the geometry core from the database of designs.

16. The method as claimed in any one of claims 1 to 14, wherein step of providing a design further comprises the step of: supplying or selecting a design of the required three-dimensional object to be generated from a database of designs of the required three-dimensional object, where in the geometry core originally used to produce the design selected from the database of designs is not known and wherein the step of determining the geometry core comprises the step of testing the design of the three-dimensional object to be generated using known geometry cores to identify the geometry core used for the design.

17. An interface for undertaking the method of any preceding claim, wherein the interface is provided with one or more selection options chosen from: a material selector for identifying the material used to generate the three-dimensional object; a contour selector for selecting the thickness of material required to generate the three-dimensional object; a robot model selector to identify a multi-axis robot used to generate the three-dimensional object; a simulation display for viewing a simulation of the motion along the tool path prior to generation of the three-dimensional object; a timer for estimating the time necessary for generating the three-dimensional object; and a material indicator for indicating the material used by and/or the material left in the extruder.

18. A system for generating three-dimensional objects from material using a multi-axis robot, said system comprising: an interface for translating a design of a three-dimensional object from a geometry core used to describe the design into a series of targets; a multi-axis robot with an extruder for extruding material to generate the three dimensional object; and a kinematic engine for placing the robot on a toolpath based on the targets.

19. The system as claimed in claim 18, wherein the extruder is configured to automatically vary the opening and closing of a nozzle to control their position and the extrusion of the material along the toolpath.

20. The system as claimed in claim 19, wherein the extruder comprises one or more adjustable blades configured within the extruder for composing a circle through which the material is extruded.

21. The system as claimed in any one of claims 18 to 20, said system further comprising: a remote interface for controlling the multiaxis robot and/or housing the interface.

22. A multi-axis robot with an arm having an extruder for extruding material to generate a three-dimensional object, the robot comprising: an interface for undertaking the method of any one of claims 1 to 16 or an interface of claim 17; motors for controlling the movement of the arm in at least 6 axial directions; a supply of material provided to the extruder for generating the three-dimensional object; and a nozzle through which the material is extruded and wherein the nozzle is opened and closed using a set of adjustable blades.

23. A computer program product for facilitating generation of a three dimensional object, the computer program product comprising a non-transitory computer-readable medium including codes for causing the computer to perform the method of any one of claims 1 to 16.

24. An extruder for directing extrusion material using a multi axis robot, said extruder comprising: a polygonal nozzle, said polygonal nozzle comprising a plurality of interconnected blades that interlock in a 1st position to provide a closed orifice for the nozzle and splay open in a 2nd position to provide an open orifice for the nozzle.

25. The extruder of claim 24, wherein the interconnected blades form exterior walls of the nozzle.

26. The extruder of claim 24 or 25, wherein the nozzle is frustoconical in the 1st position.

27. The extruder of any one of claims 24 to 26, wherein the nozzle is substantially cylindrical in the 2nd position.

28. The extruder of any one of claims 24 to 27, wherein the blades comprise fins that are exposed when the blades splay apart.

29. The extruder of any one of claims 24 to 27, wherein the extruder further comprises a ring external to the nozzle and coupled to the blades, wherein the lateral position of the ring relative to the nozzle determines the degree of splaying of the blades in the 2nd position.