Fabricating Three Dimensional Objects

• US 20170176979A1
• Filed: 08/29/2014
• Published: 06/22/2017
• Est. Priority Date: 08/29/2014
• Status: Active Grant

• Current Assignee: Microsoft Technology Licensing LLC (Microsoft Corporation)
• Original Assignee: Microsoft Technology Licensing LLC (Microsoft Corporation)
• Inventors: Tong, Xin, Gheorghescu, Gheorghe Marius, Liu, Yang, Lalish, Emmett, Jin, Yulin, Iverson, Kristofer N.
• Granted Patent: US 10,452,053 B2
• Time in Patent Office: Days
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• 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 50/00 Data acquisition or data processing for additive manufacturing
• 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 2219/35134 3-D cad-cam
• CPC Class Codes: G05B 2219/49007 Making, forming 3-D object, model, surface
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]

Abstract

The claimed subject matter includes techniques for printing three-dimensional (3D) objects. An example method includes obtaining a 3D model and processing the 3D model to generate layers of tool path information. The processing includes automatically optimizing the orientation of the 3D model to reduce an amount of support material used in the printing. The method also includes printing the 3D object using layers.

Claims

1. A system for fabricating a three-dimensional (3D) object, comprising:

a processor;

a system memory comprising code to direct the processor to;

obtain a 3D model of the 3D object;

compute, for a plurality of orientations of a 3D model, a volume of a support region used to support overhanging portions of the 3D model during printing;

identify one of the plurality of orientations of the 3D model as a selected orientation based on the volume of the support region;

orient the 3D model according to the selected orientation; and

print the 3D object.

2. The system of claim 1, comprising:

a system memory comprising code to;

process the 3D model and its support region into layers;

increase a print height and a print delay time for a layer of the 3D model printed directly adjacent a support region;

remove an internal support region for an upper layer of the 3D model if the upper layer is self-supporting; and

generate a printing path for the layers using at least one of a half-edge printing path or path of alternating right-angle turns for a sparse infill section.

3. The system of claim 2, wherein:

the upper layer of the 3D model is self-supporting if the 3D model has an over-hang angle less than 45 degrees;

the half-edge printing path adjusts such that the half-edge ends are parallel to the edge of a printing path infill region; and

the path of alternating right-angle turns are repeated in the sparse infill section to create a rectangular grid.

4. The system of claim 3, wherein:

the plurality of orientations of the 3D model are based on a convex hull of the 3D model;

the path of alternating right-angle turns are paired with a rectangular solid infill section; and

the path of alternating right-angle turns are repeated on a number of layers.

5. The system of claim 1, comprising the 3D model comprises:

a shell; and

an infill that connects to the shell by replacing a portion of the shell with additional infill.

6. A method for fabricating a three-dimensional (3D) object, the method comprising:

obtaining a 3D model of the 3D object;

computing, for a plurality of orientations of the 3D model, a volume of a support region used to support overhanging portions of the 3D model during printing;

identifying one of the plurality of orientations of the 3D model as a selected orientation based on the volume of the support region;

orienting the 3D model according to the selected orientation; and

printing the 3D object.

7. The method of claim 6, comprising increasing a print height and a print delay time for a layer of a 3D model printed directly on top of a support region layer.

8. The method of claim 6, wherein the support region comprises an internal support for an upper layer of the 3D model if the upper layer is not self-supporting.

9. The method of claim, 8 wherein the upper layer of the 3D model is self-supporting if its over-hang angle is less than 45 degrees.

10. The method of claim 6, comprising printing an infill section of a layer of a 3D model with a half-edge printing path.

11. The method of claim 6, comprising printing a sparse infill section of a layer of a 3D model following a printing path of alternating right-angle turns.

12. The method of claim 6, wherein the 3D model comprises:

a shell; and

an infill that connects to the shell by replacing a portion of the shell with additional infill.

13. The method of claim 6, comprising starting the printing of the 3D object from a concave corner of the layer, or, if the layer lacks concave corners, starting the printing from a random position on the layer.

14. One or more computer-readable memory storage devices for storing computer readable instructions that, when executed by one or more processing devices, instruct the fabrication of a 3D object, the computer-readable instructions comprising code to:

obtain a 3D model of the 3D object;

compute, for a plurality of orientations of a 3D model, a volume of a support region to support overhanging portions of the 3D model during printing;

identify one of the plurality of orientations of the 3D model as a selected orientation based on the volume of the support region;

orient the 3D model according to the selected orientation; and

print the 3D object.

15. The one or more computer-readable memory storage devices of claim 14, wherein the 3D model comprises:

a shell of a layer; and

an infill that connects to the shell of a layer by replacing a portion of the shell with additional infill.

16. The one or more computer-readable memory storage devices of claim 14, the computer-readable instructions comprising code to increase a print height and a print delay time for a layer of the 3D model to be printed adjacent a support region layer.

17. The one or more computer-readable memory storage devices of claim 14, wherein the plurality of orientations of the 3D model are based on the number of faces generated by the convex hull of the 3D model.

18. The one or more computer-readable memory storage devices of claim 14, the computer-readable instructions comprising code to remove an internal support region for an upper layer of the 3D model if the upper layer is self-supporting.

19. The one or more computer-readable memory storage devices of claim 14, the computer-readable instructions comprising code to:

generate a printing path for an infill using a half-edge printing path; and

generate a grid by a plurality of printing paths which alternate direction of right-angle turns in a sparse infill section.

20. The one or more computer-readable memory storage devices of claim 19, wherein:

the path of alternating right-angle turns are paired with a rectangular solid infill section; and

the path of alternating right-angle turns are repeated on each layer the sparse infill section is present.