In one embodiment of the present invention, a print orientation tool efficiently determines an orientation of a three-dimensional (3D) model such that, when 3D printed, the structural integrity of the resulting 3D object is optimized. In operation, the print orientation tool configures a stress analysis engine to slice the 3D model into two-dimensional (2D) cross-sections. The stress analysis engine then compute structural stresses associated with the 2D cross-sections. The print orientation tool translates the structural stresses to weakness metrics. Subsequently, the print orientation tool evaluates the orientations of the cross-sections in conjunction with the corresponding weakness metrics to select a printing orientation that minimizes weaknesses in the 3D model. Advantageously, by aligning the 3D model to the print bed based on the optimized printing orientation, the user mitigates weaknesses in the corresponding 3D object attributable to the 3D printing manufacturing process.

Algorithmic reasoning about a cutting tool assembly's space of feasible configurations can be effectively harnessed to construct a sequence of motions that guarantees a collision-free path for the tool assembly to remove each support structure in the sequence. A greedy algorithm models the motion of the cutting tool assembly through the free-spaces around the intermediate shapes of the part as the free-spaces iteratively reduce in size to the near-net shape to determine feasible points of contact for the cutting tool assembly. Each support beam is evaluated for a contact feature along the boundary of the near-net shape that constitutes a feasible point of contact. If a support beam has at least one feasible configuration at each point, the support beam is deemed accessible and a collection of tool assembly configurations that are guaranteed to be non-colliding but which can access all points of contact of each accessible support beam can be generated.

Algorithmic reasoning about a cutting tool assembly's space of feasible configurations can be effectively harnessed to construct a sequence of motions that guarantees a collision-free path for the tool assembly to remove each support structure in the sequence. A greedy algorithm models the motion of the cutting tool assembly through the free-spaces around the intermediate shapes of the part as the free-spaces iteratively reduce in size to the near-net shape to determine feasible points of contact for the cutting tool assembly. Each support beam is evaluated for a contact feature along the boundary of the near-net shape that constitutes a feasible point of contact. If a support beam has at least one feasible configuration at each point, the support beam is deemed accessible and a collection of tool assembly configurations that are guaranteed to be non-colliding but which can access all points of contact of each accessible support beam can be generated.

The exemplified methods and systems facilitate manufacturing of a new class of mechanical, loading-bearing components having optimized stress/strain three-dimensional meta-structure structures (also referred to herein as Meshagons) as finite-element-based 3D volumetric mesh structures. The resulting three-dimensional meta-structure structures provide high strength, ultra-light connectivity, with programmable interlinkage properties (e.g., density/porosity of linkages).

In one embodiment of the present invention, a print orientation tool efficiently determines an orientation of a three-dimensional (3D) model such that, when 3D printed, the structural integrity of the resulting 3D object is optimized. In operation, the print orientation tool configures a stress analysis engine to slice the 3D model into two-dimensional (2D) cross-sections. The stress analysis engine then compute structural stresses associated with the 2D cross-sections. The print orientation tool translates the structural stresses to weakness metrics. Subsequently, the print orientation tool evaluates the orientations of the cross-sections in conjunction with the corresponding weakness metrics to select a printing orientation that minimizes weaknesses in the 3D model. Advantageously, by aligning the 3D model to the print bed based on the optimized printing orientation, the user mitigates weaknesses in the corresponding 3D object attributable to the 3D printing manufacturing process.

According to some embodiments, an industrial asset item definition data store may contain at least one electronic record defining the industrial asset item. An automated support structure creation platform may include a support structure optimization computer processor. The automated support structure optimization computer processor may, for example, be adapted to automatically create support structure geometry data associated with an additive printing process for the industrial asset item. The creation may be performed, according to some embodiments, via an iterative loop between a build process simulation engine and a topology optimization engine.

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.

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.

An information processing apparatus for providing data for modeling to an additive manufacturing apparatus that models a modeling object by repeatedly stacking layers of material is provided. The information processing apparatus includes a volume calculation unit configured to calculate a volume of the modeling target and a support-part-modeling-method determination unit configured to determine a modeling method of a support part that supports the modeling target according to the volume.

An arrangement determining apparatus includes a storing processor that stores data of a three-dimensional model of the target object, a reference processor that shifts and rotates the three-dimensional model, a center-of-gravity calculating processor that calculates a center of gravity of the three-dimensional model, a principal axis setting processor that calculates a farthest point that is most distant from the center of gravity of the three-dimensional model, and sets a principal axis connecting the center of gravity of the three-dimensional model and the farthest point, a tilting processor that tilts the three-dimensional model so that the principal axis is parallel or substantially parallel to a horizontal plane, and an arranging processor that attaches and arranges the supports on a top surface or a bottom surface of the three-dimensional model.