Fabricating three-dimensional objects with overhang

• US 10,434,717 B2
• Filed: 06/20/2017
• Issued: 10/08/2019
• Est. Priority Date: 03/03/2014
• Status: Active Grant

• Current Assignee: Microsoft Technology Licensing LLC (Microsoft Corporation)
• Original Assignee: Microsoft Technology Licensing LLC (Microsoft Corporation)
• Inventors: Boettcher, Shanen J., Jin, Yulin, Lalish, Emmett, McGatha, Jesse
• Primary Examiner(s): Dunn, Darrin D
• Application Number:
  US15/628,424
• Publication Number:
  US 20170348915A1
• Time in Patent Office: 840 Days
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/40 Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G06T 11/203 Drawing of straight lines or curves
• CPC Class Codes: G06T 17/10 Constructive solid geometry [CSG] using solid primitives, e.g. cylinders, cubes

Abstract

The claimed subject matter includes a system and method to design 3D objects for fabrication. In embodiments, the method includes sampling coordinates of a two-dimensional object. The method also includes generating fabrication coordinates based on the sampled coordinates and a plane comprising a top layer of a three-dimensional (3D) object. Additionally, the method includes generating a 2D triangular mesh for the top layer of an overhang based on the sampled coordinates, an angle between the top layer and two points in a previous top layer border less than or equal to an overhang threshold angle.

Claims

1. A method for creating a three-dimensional (3D) model of a feature from a two-dimensional (2D) image, and integrating the 3D model of the feature into a 3D object model that can be manufactured without requiring support material, the method comprising:

identifying an edge of a shape of the 2D image;

determining a curve that substantially fits the edge of the 2D image shape;

sampling the curve to determine coordinates on the curve;

generating straight-line segments between the determined coordinates;

generating a 2D triangular mesh of the 2D image shape based on the straight-line segments;

determining a height of a third dimension based on at least one of a distance between two coordinates on the curve, a chamfer angle, and a specified height;

transforming the 2D triangular mesh of the 2D image shape into a 3D model feature by duplicating 2D polygons of the 2D triangular mesh;

adjusting the duplicated 2D polygons to fit a surface area of the determined height;

merging the 2D polygons of the 2D triangular mesh with the adjusted duplicated 2D polygons to create a 3D triangular mesh of the 3D model feature of the 2D image shape; and

merging the 3D triangular mesh of the 3D model feature with a 3D triangular mesh of the 3D object model.

2. The method of claim 1, comprising determining an offset of a layer of the 3D object model from a 3D object based on the height of the third dimension and the adjustment made to form the adjusted duplicated 2D polygons.

3. The method of claim 2, wherein the offset of the layer of the 3D object model from the 3D object results in an offset with an angle less than 45 degrees relative to a surface of the 3D object.

4. The method of claim 1, wherein generating the 2D triangular mesh of the 2D image shape uses a triangulation method based on the determined coordinates on the curve.

5. The method of claim 1, wherein the 3D model comprises ridges formed by intersecting chamfers, the chamfer having angles less than 45 degrees relative to a 3D object.

6. The method of claim 1, wherein the merging of the 2D polygons of the 2D triangular mesh with the adjusted duplicated 2D polygons does not refine any segment of an original outer polygon of a 3D object.

7. The method of claim 1, comprising fabricating the 3D object model with extrudable material to match with an outer surface of the 3D object model of a 3D object.

8. The method of claim 7, wherein the 3D object model comprises a projection of specific text that is embossed on a side, top, or bottom of the 3D object.

9. A system for creating a three-dimensional (3D) model of a feature from a two-dimensional (2D) image, and integrating the 3D model of the feature into a 3D object model that can be manufactured without requiring support material, comprising:

a processing unit; and

a system memory, wherein the system memory comprises code configured to direct the processing unit to;

identify an edge of a shape of the 2D image;

determine a curve that substantially fits the edge of the 2D image shape;

sample the curve to determine coordinates on the curve;

generate straight-line segments between the determined coordinates;

generate a 2D triangular mesh of the 2D image shape based on the straight-line segments;

determine a height of a third dimension based on at least one of a distance between two coordinates on the curve, a chamfer angle, and a specified height;

transform the 2D triangular mesh of the 2D image shape into a 3D model feature by duplicating 2D polygons of the 2D triangular mesh;

adjust the duplicated 2D polygons to fit a surface area of the determined height;

merge the polygons of the 2D triangular mesh with the adjusted duplicated 2D polygons to create a 3D triangular mesh of the 3D model feature of the 2D image shape; and

merge the 3D triangular mesh of the 3D model feature with a 3D triangular mesh of the 3D object model.

10. The system of claim 9, wherein the system memory comprises code configured to direct the processing unit to determine an offset of a layer of the 3D object model from a 3D object based on the height of the third dimension and the adjustment made to form the adjusted duplicated 2D polygons.

11. The system of claim 10, wherein the offset of the layer of the 3D object model from a 3D object results in an offset with an angle less than 45 degrees relative to a surface of the 3D object.

12. The system of claim 9, wherein generating the 2D triangular mesh of the 2D image shape uses a triangulation method based on the determined coordinates of the curve.

13. The system of claim 9, wherein the 3D model comprises ridges formed by intersecting chamfers, the chamfer having angles less than 45 degrees relative to a 3D object.

14. The system of claim 9, wherein the merging of the 2D polygons of the 2D triangular mesh with the adjusted duplicated 2D polygons does not refine any segment of an original outer polygon of a 3D object.

15. The system of claim 9, wherein the system memory comprises code configured to direct the processing unit to fabricate the 3D object model with extrudable material to match with an outer surface of the 3D object model of a 3D object.

16. One or more computer-readable memory storage devices that store computer-readable instructions for creating a three-dimensional (3D) model of a feature from a two-dimensional (2D) image, and integrating the 3D model of the feature into a 3D object model that can be manufactured without requiring support material, the instructions when executed by one or more processing devices are configured to:

determine a 2D line based on a plurality of boundaries of a 2D object, wherein the 2D line represents a top layer of a 3D object, and wherein the 3D object is a 3D representation of the 2D object, with overhang, and wherein the top layer represents a ridge of a 3D roof that is disposed midway between two boundaries of a bottom layer of the 3D object;

determine the 3D roof of the 3D object based on the 2D line, the plurality of boundaries, a specified angle of the 3D roof, and a specified chamfer that connects two surfaces of the 3D roof, wherein the 3D roof comprises a plurality of layers, and wherein a layer of the plurality of layers is offset in an x and y direction of the 3D object within a supporting layer, wherein the supporting layer is in contact with the layer, and wherein the supporting layer supports the layer in a z direction of the 3D object, and wherein the specified angle of the 3D roof is less than 45 degrees with respect to the top layer and a boundary of a bottom layer of the 3D object;

generate a model of the 3D object for fabrication, wherein the model is generated based on the 3D roof and the 2D object.

17. The one or more computer-readable memory storage devices of claim 16, wherein the stored computer-readable instructions when executed by one or more processing devices are further configured to direct the one or more processing devices to determine a layer offset for the 3D object model of the 3D object based on a height of a third dimension of the 3D object and on an adjustment made for 2D polygons of a generated 2D triangular mesh.

18. The one or more computer-readable memory storage devices of claim 17, wherein the determined layer offset for the 3D object model of the 3D object results in an offset angle less than 45 degrees relative to a surface of the 3D object.

19. The one or more computer-readable memory storage devices of claim 16, wherein the stored computer-readable instructions when executed by one or more processing devices are further configured to direct the one or more processing devices to generate a 2D triangular mesh of a 2D image shape for the 3D object using a triangulation method based on sampled coordinates of a curve that substantially fits an edge of the 2D image shape.

20. The one or more computer-readable memory storage devices of claim 16, wherein the 3D model of a feature from a two-dimensional (2D) image comprises ridges formed by intersecting chamfers, each chamfer having angles less than 45 degrees relative to the 3D object.