GENERATING SUPPORT MATERIAL FOR THREE-DIMENSIONAL PRINTING

• US 20150151493A1
• Filed: 06/09/2014
• Published: 06/04/2015
• Est. Priority Date: 12/03/2013
• Status: Active Grant

• Current Assignee: Autodesk, Inc.
• Original Assignee: Autodesk, Inc.
• Inventors: SCHMIDT, Ryan Michael
• Granted Patent: US 10,226,895 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/49038 Support help, grid between support and prototype, separate easily
• CPC Class Codes: G06F 2119/18 Manufacturability analysis or optimisation for manufacturability
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

In one embodiment of the present invention, a support structure generator creates support structures designed to buttress three-dimensional (3D) digital models during 3D printing. In operation, the support structure generator incrementally constructs a support graph that connects overhanging points included in the 3D model with support points on a horizontal ground plane or relatively flat surfaces in the 3D model. After generating the 3D model, the support structure generator translates the connections between the nodes into support posts sized to sufficiently support the connected surfaces with the minimum amount of support material. Advantageously, the support structure is noticeably sparser than conventional support structures that fill a given support region with a solid volume of support material. Consequently, the time necessary for 3D printers to fabricate the support structure of interconnected support posts is less than the time required for 3D printers to fabricate conventional support structures.

Claims

1. A computer-implemented method for selecting support points included in support structures implemented when printing three-dimensional models, the method comprising:

applying a first constraint to a first unsupported point included in a support structure to identify a candidate region, wherein the support structure is connected to a three-dimensional model;

evaluating the candidate region to determine a first support point, wherein the first support point comprises a point included within the candidate region that is closest to the three-dimensional model; and

generating a first support post between the first unsupported point and the first support point.

2. The method of claim 1, wherein the first constraint comprises a vertical distance between the first unsupported point and the candidate region.

3. The method of claim 2, wherein the candidate region comprises a horizontal plane.

4. The method of claim 1, wherein the first constraint comprises a maximum acceptable angle of a line relative to a horizontal ground plane, wherein the line extends from the first unsupported point to the first support point.

5. The method of claim 1, wherein the first constraint comprises a minimum acceptable distance between the first unsupported point and any point included in the three-dimensional model.

6. The method of claim 1, wherein the first support post resides at an angle that is less than ninety relative to a horizontal ground plane.

7. The method of claim 1, wherein the first unsupported point is located within an overhanging surface of the three-dimensional model.

8. The method of claim 1, further comprising:

applying a second constraint to a second unsupported point included in the support structure to identify both a first candidate point and a second candidate point;

calculating a first Manhattan distance between the first candidate point and the second unsupported point;

calculating a second Manhattan distance between the second candidate point and the second unsupported point;

comparing the first Manhattan distance and the second Manhattan distance; and

if the first Manhattan distance exceeds the second Manhattan distance, then generating a second support post between the second unsupported point and the second candidate point, or

if the first Manhattan distance does not exceed the second Manhattan distance, then generating a second support post between the second unsupported point and the second candidate point.

9. The method of claim 8, wherein the second candidate point is located within either a horizontal ground plane or the three-dimensional object.

10. A computer-readable storage medium including instructions that, when executed by a processing unit, cause the processing unit to select support points included in support structures implemented when printing three-dimensional models by performing the steps of:

applying a first constraint to a first unsupported point included in a support structure to identify a candidate region, wherein the support structure is connected to a three-dimensional model;

evaluating the candidate region to determine a first support point, wherein the first support point comprises a point included within the candidate region that is closest to the three-dimensional model; and

generating a first support post between the first unsupported point and the first support point.

11. The computer-readable storage medium of claim 10, wherein the first constraint comprises a vertical distance between the first unsupported point and the candidate region.

12. The computer-readable storage medium of claim 11, wherein the candidate region comprises a horizontal plane.

13. The computer-readable storage medium of claim 10, wherein the first constraint comprises a maximum acceptable angle of a line relative to a horizontal ground plane, wherein the line extends from the first unsupported point to the first support point.

14. The computer-readable storage medium of claim 10, wherein the first constraint comprises a minimum acceptable distance between the first unsupported point and any point included in the three-dimensional model.

15. The computer-readable storage medium of claim 10, wherein the first support post resides at an angle that is less than ninety relative to a horizontal ground plane.

16. The computer-readable storage medium of claim 10, wherein the first unsupported point is located within an overhanging surface of the three-dimensional model.

17. The computer-readable storage medium of claim 10, further comprising:

applying a second constraint to a second unsupported point included in the support structure to identify both a first candidate point and a second candidate point;

calculating a first Manhattan distance between the first candidate point and the second unsupported point;

calculating a second Manhattan distance between the second candidate point and the second unsupported point;

comparing the first Manhattan distance and the second Manhattan distance; and

if the first Manhattan distance exceeds the second Manhattan distance, then generating a second support post between the second unsupported point and the second candidate point, or

if the first Manhattan distance does not exceed the second Manhattan distance, then generating a second support post between the second unsupported point and the second candidate point.

18. The computer-readable storage medium of claim 17, wherein the second candidate point is located within either a horizontal ground plane or the three-dimensional object.

19. A system configured to select support points included in support structures implementing when printing three-dimensional models, the system comprising:

a processing unit configured to;

apply a first constraint to a first unsupported point included in a support structure to identify a candidate region, wherein the support structure is connected to a three-dimensional model;

evaluate the candidate region to determine a first support point, wherein the first support point comprises a point included within the candidate region that is closest to the three-dimensional model; and

generate a first support post between the first unsupported point and the first support point; and

a three-dimensional printing unit coupled to the processing unit and configured to implement the three-dimensional model and the support structure.

20. The system of claim 19, wherein the first constraint comprises a maximum acceptable angle of a line relative to a horizontal ground plane, wherein the line extends from the first unsupported point to the first support point.