Object model data is obtained, representing one or more objects to be generated by an additive manufacturing system. An object model is generated, representing an arrangement of the one or more objects within a build volume, by determining a solution to a packing optimization function. A layer of the object model is analysed to determine a parameter representing the complexity of the layer, and if the determined parameter exceeds a given threshold, the process is repeated by generating a revised object model representing a different arrangement of the one or more objects within the build volume.

Methods and computer systems for utilizing gapless surface models in computer-aided design (CAD) applications to produce printing instructions for additive manufacturing (AM). A geometrically watertight CAD spline model of an object to be printed is received. For of a plurality of AM layers of the object, an intersection routine is performed of a plane of the layer with the geometrically watertight CAD spline model to obtain a respective smooth contour curve. For each AM layer, a plurality of hatch curves is determined within the plane of the layer and interior to the respective smooth contour curve. The smooth contour curves and the pluralities of hatch curves are stored in a non-transitory computer-readable memory medium.

A method of forming a representative part correlating to an actual part. The method includes receiving an actual part design, analyzing the actual part design to identify one or more design elements, based on the one of more design elements; generating a representative part design incorporating the one or more design elements and having a differing overall shape comparative to the actual part design, and forming a representative part based on representative part design. A representative part correlating to an actual part includes one or more design elements of the actual part and a different overall shape relative to the actual part. A method of qualifying an additive manufacturing system or process for forming an actual part.

A computer-implemented method of incarnating a self-intersecting lattice structure as a mesh in a three-dimensional model is described. A pair of bodies in the lattice is chosen. An initial set of sample points is created by intersecting a set of constant parameter curves within the parameter range lying on the surface of one of the bodies of the pair with the surface of the other body of the pair. Chords between adjacent sample points in the initial set of samples that lie within a pre-determined tolerance of the surfaces of both bodies in the pair are calculated and iterated over until all the sample points are within the pre-determined tolerance. Once this is done for all bodies in the lattice, a mesh is incarnated.

A computing device comprising a processor is disclosed herein. The processor is to access print data of a virtual build volume including a plurality of 3D objects to be generated through a selective application of a binder agent by a 3D printer. The processor is further to modify the print data to include a 3D structure at a location within the build volume to protect a 3D object from migrating solvents of the binder agent during a curing operation.

An apparatus for manufacturing a three-dimensional article by additive manufacturing includes a processor and an information storage device storing software instructions. In response to execution by the processor, the software instructions cause the apparatus to: receive initial data defining the three-dimensional article having an outer surface, define a shell having the outer surface of the three-dimensional article and an opposing inner surface that defines an inner cavity, define a transition zone between the inner surface of the shell and a boundary that is inside the inner cavity and generally follows the inner surface of the shell, define a lattice of arrayed unit cells that fill the inside of the boundary, the lattice is defined by connected lattice segments, and define transition segments that couple the lattice to the inner surface of the shell.

A method includes identifying machine process parameters for an additive manufacturing process to produce a part, providing a real-world sensor to sense a characteristic associated with a real-world version of the additive manufacturing process, receiving sensor readings from the real-world sensor while the machine is performing the real-world version of the additive manufacturing process, generating, with a computer-based processor, physics-based features associated with the additive manufacturing process, and training a machine-learning software model based at least in part on the machine process parameters, the sensor readings, and the physics-based features to predict a behavior of the real-world sensor.

A layered modeling method for laser metal deposition (LMD) 3D printing. The layered modeling method includes: obtaining estimated printing parameters of each layer in an entire digital model based on a process database; obtaining estimated feature points of each layer through the estimated parameters; comparing estimated feature points of each layer with feature points of a corresponding actual shape to obtain a difference in each layer; and accumulating to obtain a difference in the entire digital model to obtain corresponding printing parameters. The layered modeling method has the advantages of effectively reducing the calculation amount during data comparison and greatly saving time.

In an example, a method includes receiving, at a processor, an object model describing a geometry of a three-dimensional object, and determining a transformed data model describing a volume containing a modified version of the three-dimensional object as a plurality of categorised contiguous, non-overlapping sub-volumes, wherein the modified version of the three-dimensional object includes a surface offset. Determining the transformed data model may comprises categorising the sub-volumes by defining a first region by determining an area swept by an offset operator when the offset operator is swept around a boundary of the sub-volume and defining a second region, interior to the first region, and indicative of the closest approach of the offset operator to the sub-volume when the offset operator is swept around the boundary. Intersections between a surface of the object model and at least one of the first and second region may be determined. When the surface intersects the second region, the sub-volume may be categorised as interior to the three-dimensional object; and when the surface intersects the first region and not the second region, the sub-volume may categorised as spanning a boundary of the three-dimensional object.

According to examples, an apparatus may include a processor that may access a digital model of an item to be fabricated to have a plurality of features, in which the digital model may include a surface. The processor may pack a plurality of digital ellipsoids to intersect the surface of the digital model of the item, in which the plurality of digital ellipsoids are arranged with respect to each other based on a curvature of the surface. The processor may also determine locations on the surface at which the plurality of digital ellipsoids intersect the surface and may set the determined locations as points on the surface at which the plurality of features are to be formed.