Implicit method and an algorithm for flexible functionally tailorable slicing for additive manufacturing

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  • Publication Date:
    September 14, 2021
  • Additional Information
    • Patent Number:
      11119,466
    • Appl. No:
      15/829088
    • Application Filed:
      December 01, 2017
    • Abstract:
      A method for flexible functionally tailorable slicing for additive manufacturing includes the steps of receiving and parsing an input model of an object to be additively manufactured; reconstructing a domain boundary of the object; computing individual layer boundaries of the object; constructing, for each layer, layer domains from respective enclosing boundaries; computing, for each layer, a perimeter shell and a volumetric infill by finding level sets of a field function selected by a user; collecting and arranging into a coherent sequence each perimeter shell and volumetric infill; and formatting the coherent sequence as motion commands for an additive manufacturing system.
    • Inventors:
      The Government of the United States of America, as represented by the Secretary of the Navy (Arlington, VA, US)
    • Assignees:
      The Government of the United States of America, as represented by the Secretary of the Navy (Washington, DC, US)
    • Claim:
      1. A method for flexible functionally tailorable slicing for additive manufacturing, the method including the steps of: receiving an input model of an object to be additively manufactured; parsing the input model; reconstructing a domain boundary of the object; computing individual layer boundaries of the object; constructing, for each layer, layer domains from respective enclosing boundaries; computing, for each layer, a perimeter shell by finding level sets of distance function applied to the boundaries; computing, for each layer, a volumetric infill by finding level sets of a specified field function; collecting and arranging into one or more contiguous ordered sets of line segments each perimeter shell and volumetric infill from each layer; and formatting the one or more contiguous ordered sets of line segments as motion commands for a target additive manufacturing system.
    • Claim:
      2. The method of claim 1 , wherein the step of computing individual layer boundaries includes intersecting a series of parallel planes with the domain boundary.
    • Claim:
      3. The method of claim 1 , wherein the step of computing individual layer boundaries includes partitioning subdomain boundaries into contiguous ordered subsets of line segments.
    • Claim:
      4. The method of claim 1 , wherein the step of constructing, for each layer, layer domains includes utilizing constrained Delaunay triangulation to define the layer domains as a set of planar facets.
    • Claim:
      5. The method of claim 1 , wherein the step of computing, for each layer, a volumetric infill by finding level sets of a field function selected by a user includes solving a partial differential equation or system of such equations with user-specified boundary conditions on the domain boundary.
    • Claim:
      6. The method of claim 1 , wherein the step of computing, for each layer, a volumetric infill by finding level sets of a field function selected by a user includes basing the volumetric infill on relevant physical fields computed by computational simulation.
    • Claim:
      7. The method of claim 1 , wherein the field function is a user-specified modulation of another field function based on relevant physical fields as computed by the solution of one or more partial differential equations or of computational simulation.
    • Claim:
      8. The method of claim 1 , further comprising the step of: interfacing with a simulation tool for material mechanics; and wherein the specified field function is automatically generated based on computed results of the simulation tool.
    • Claim:
      9. The method of claim 1 , further comprising the step of: interfacing with one or more external data sources or databases; and wherein the field function selected by a user is automatically generated based on experimental data from the one or more external data sources or databases.
    • Claim:
      10. The computer program product of claim 1 , wherein the specified field function is selected by a user.
    • Claim:
      11. A computer program product stored on a non-transitory computer-readable medium, the computer program product configured to cause one or more processors to execute the method comprising the steps of: receiving an input model of an object to be additively manufactured; parsing the input model; reconstructing a domain boundary of the object; computing individual layer boundaries of the object; constructing, for each layer, layer domains from respective enclosing boundaries; computing, for each layer, a perimeter shell by finding level sets of distance function applied to the boundaries; computing, for each layer, a volumetric infill by finding level sets of a specified field function; collecting and arranging into one or more contiguous ordered sets of line segments each perimeter shell and volumetric infill from each layer; and formatting the one or more contiguous ordered sets of line segments as motion commands for a target additive manufacturing system.
    • Claim:
      12. The computer program product of claim 11 , wherein the step of computing individual layer boundaries includes intersecting a series of parallel planes with the domain boundary.
    • Claim:
      13. The computer program product of claim 11 , wherein the step of computing individual layer boundaries includes partitioning subdomain boundaries into contiguous ordered subsets of line segments.
    • Claim:
      14. The computer program product of claim 11 , wherein the step of constructing, for each layer, layer domains includes utilizing constrained Delaunay triangulation to define the layer domains as a set of planar facets.
    • Claim:
      15. The computer program product of claim 11 , wherein the step of computing, for each layer, a volumetric infill by finding level sets of a field function selected by a user includes solving a partial differential equation or system of such equations with user-specified boundary conditions on the domain boundary.
    • Claim:
      16. The computer program product of claim 11 , wherein the step of computing, for each layer, a volumetric infill by finding level sets of a field function selected by a user includes basing the volumetric infill on stress or strain fields computed by computational simulation.
    • Claim:
      17. The computer program product of claim 11 , wherein the field function is a user-specified modulation of another field function based on relevant physical fields as computed by the solution of one or more partial differential equations or of computational simulation.
    • Claim:
      18. The computer program product of claim 11 , further comprising the step of: interfacing with a simulation tool for material mechanics; and wherein the specified field function is automatically generated based on computed results of the simulation tool.
    • Claim:
      19. The computer program product of claim 11 , further comprising the step of: interfacing with one or more external data sources or databases; and wherein the field function selected by a user is automatically generated based on experimental data from the one or more external data sources or databases.
    • Claim:
      20. The computer program product of claim 11 , wherein the specified field function is selected by a user.
    • Patent References Cited:
      2016/0096318 April 2016 Bickel
      2018/0052433 February 2018 Vernon
      2018/0250748 September 2018 Page
    • Other References:
      Adams, D and C. J. Turner, “An Implicit Slicing Method for Additive Manufacturing Processes”, 2017, Journal: Virtual and Physical Prototyping, vol. 13, No. 1, pp. 2-7 (Year: 2017). cited by examiner
    • Assistant Examiner:
      Rao, Sheela
    • Primary Examiner:
      Ali, Mohammad
    • Attorney, Agent or Firm:
      US Naval Research Laboratory
      Bis, Richard
    • Accession Number:
      edspgr.11119466