Three-Dimensional (3D) Printing and CAD File Quoting System

Abstract

A system and method for a three-dimensional (3D) printing quoting tool and system is provided for in the present invention. The 3D printing tools contemplated are capable of taking information from and presenting information to customers in order for the customer to have selective input into various aspects of such design and fabrication which affect price of a customized 3D part, and the printer to accurately price a customized 3D part.

Claims

1. A method for optimizing the printing of a three-dimensional (3D) printed object comprising: (a) receiving a 3D model of a 3D object at a processing system; (b) analyzing at the processing system the 3D model and generating a 3D envelope around said model, the 3D envelope corresponding to the X, Y, and Z dimensions of the 3D model; (c) instantiating at the processing system a buildable area and a support surface; (d) displaying the 3D model, buildable area, and support surface in a graphical user interface (GUI); (e) optimizing the orientation of the 3D model to minimize support structure; and (f) analyzing at the processing system the 3D model to detect any defects that would prevent proper printing of the 3D object.

2. The method of claim 1 wherein the user can selectively hide the support structure in the GUI.

3. The method of claim 1 further comprising: (g) scaling the 3D model within the quote generation system.

4. The method of claim 1 wherein (f) comprises detecting thin walls.

5. The method of claim 1 wherein (f) comprises detecting non-manufacturable holes.

6. The method of claim 1 wherein (f) comprises detecting non-manufacturable dimensions.

7. The method of claim 1 further comprising: (g) notifying the user when a defect is determined in (f).

8. The method of claim 1 further comprising: (g) printing the 3D object.

9. The method of claim 1, further comprising: (g) calculating a price quote for printing the 3D object based in part on the optimized orientation determined in (e).

10. The method of claim 9, wherein (g) comprises considering a number of changes in printing heads.

11. The method of claim 9, wherein (g) comprises considering an amount of material wasted during the printing process.

12. The method of claim 9, wherein (g) comprises a consideration of a time required to print the 3D object.

13. A method of manufacturing a 3D object, the method comprising: optimizing a 3D model of the 3D object for printing with a 3D printer comprising: (a) receiving a 3D model of a 3D object at a processing system; (b) analyzing at the processing system the 3D model and generating a 3D envelope around said model, the 3D envelope corresponding to the X, Y, and Z dimensions of the 3D model; (c) instantiating at the processing system a buildable area and a support surface; (d) displaying the 3D model, buildable area, and support surface in a graphical user interface (GUI); (e) optimizing the orientation of the 3D model to minimize support structure; (f) analyzing at the processing system the 3D model to detect any defects that would prevent proper printing of the 3D object; and printing the 3D object with a 3D printer.

14. The method of claim 13, further comprising: (g) calculating a price quote for printing the 3D object based in part on the optimized orientation determined in (e).

15. The method of claim 13, wherein (g) comprises a consideration of a number of changes in printing heads.

16. The method of claim 13, wherein (g) comprises a consideration of an amount of material wasted during the printing process.

17. The method of claim 13, wherein (g) comprises a consideration of a time required to print the 3D object.

18. The method of claim 13 wherein (f) comprises detecting thin walls.

19. The method of claim 13 wherein (f) comprises detecting non-manufacturable holes.

20. The method of claim 13 wherein (f) comprises detecting non-manufacturable dimensions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Other features of my invention will become more evident from a consideration of the following brief descriptions of drawings:

[0021] FIG. 1 is a perspective view of a representative 3D part shown within the price quoting system according to the present invention.

[0022] FIG. 2 is a perspective view of a representative 3D part shown within the price quoting system with an additional support structure shown according to the present invention.

[0023] FIG. 3 is a perspective view of the representative 3D part of FIG. 1 reoriented within the price quoting system of the present invention.

[0024] FIG. 4 is a perspective view of the representative 3D part reoriented as in FIG. 3 with a rebuilt additional support structure.

[0025] FIG. 5 is a perspective view of a representative 3D part shown within the price quoting system with functional options demonstrated.

[0026] FIG. 6 shows exemplary transactions for pricing a 3D printing job using the system of the present invention.

[0027] FIG. 7 is a representative quote as output by the current invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0028] Referring now to the drawings with more specificity, the present invention essentially provides a three-dimensional (3D) printing and CAD file quoting system, or a viewer and quote engine for 3D parts corresponding to the 3D printing of those parts. Using the present invention, a user may import a file from his computer into the 3D quoting system and receive a price quote from the system based on the size, scope, orientation, and other relevant factors related to the part. In addition, the system can be programmed with several other variables and features discussed below.

[0029] Looking now to FIG. 1 a representative 3D part 20 is show in the 3D quoting system's Graphical User Interface (GUI) 10. Part 20 will typically represent a user's Stereolithography (SLA) format file, but other file formats are contemplated for use with the 3D quoting system through conversion and direct implementation. The GUI will typically involve drop down menus, radio buttons, and other conventional features that allow the user to select the process for making the part, color, density, finish, and other factors. In addition to conventional features of a 3D price quoting system, the system of the present invention includes a representative printing tray or support surface 11. The printing tray 11 can be scaled to represent the tray or surface of the 3D printing machine corresponding to the printing process the user selects (such as FDM, SLS, SLA, or other printing processes). Also unique to the present invention is the system's construction of an envelope or boxed border 30 around 3D part 20.

[0030] Envelope 30 shows a graphical representation of the X (31), Y (33), and Z (32) dimensions of the part as it is currently orientated. This envelope shows to the user the footprint of the part 20 within the build space 10, and particularly the footprint on printing tray 11. In certain configurations, additional parts will be able to be manufactured simultaneously depending on the part's footprint, thereby affecting the price quote. In certain situations, diagonals 34 are also shown in the envelope and may confer to the user additional information.

[0031] As can be seen in FIGS. 1 & 2 and additionally in other orientations in FIGS. 3 & 4, the price quotation system consistently can orient the part such that it is touching or adjacent to the printing tray 11. This is a necessary step for generating support structure 40 which connects portions of piece 20 to tray 11 and supports them during the printing process. Support material is essential to the majority of modern 3D printing processes. A part (such as part 20) is printed one layer at a time, and without support material essential portions of the 3D printed part will fall to the base tray, into the undercuts, or through hollow features as the part is being printed. Thus, support material, or support structures 40 are used to hold layers in place and keep the base material out of the way.

[0032] Typical 3D printing quoting systems have no way of accurately modeling support material 40. Mistakes in estimating the amount of support material used in printing often exceed 50% of the cost of printing the part. Thus, support structure (along with part size, time to print, and other factors) is a major factor in driving costs for the manufacturer and failures in estimation can cause major cost overruns. Thus, as can be seen in FIGS. 2 & 4 the system of the current invention can generate and pre-render the support structure dynamically as the part is oriented within the space 10. And as can be seen, different support structures can be constructed for the same part depending on the orientation and reorientation of the part. The current system can estimate the total amount of support structure used with less than 10% error and typically in most cases the error is less than 5%.

[0033] One additional cost driver of present 3D printing processes is that printers typically must switch between separate printing heads when printing support material 40 and the part 20. This is essential as the support material is constructed from a different composition for simple removal later (some implementations utilize chemical baths to dissolve support structure). Changing and cleaning printer heads takes time and thus increases the cost of manufacturing a part. For example, printing at boundary 21 (seen in FIGS. 2 & 4) requires a change from printing support structure 40 to part 20 necessitating a change in printer heads. Thus, one additional benefit of the current system is that by accurately rendering support structure 40, the system can also accurately calculate the number of times the printer heads will have to trade off, and estimate the time and cost associated with those changes, greatly increasing the accuracy of the final price quote.

[0034] As can be seen with greater specificity in FIGS. 3 & 4, one critical aspect of the current invention is the ability of the user to re-orient the 3D part 20 within the interface 10 and the system's ability to automatically reconfigure and recalculate the support structure 40. The user can choose to reorient the part 20 around any of its X, Y, or Z axes thus giving the user total control over the printing process. While the system may also have an auto orient feature that will minimize the cost for the consumer, certain parts will have intricate features that a user may not want to be exposed to support structure. By way of example, a user may desire the orientation of FIGS. 3 & 4 as side 22 of the part 20 is not supported by support structure on the exterior. If there are details, such as a logo, being 3D printed on that side of the part, this orientation would preserve the integrity of those fine features.

[0035] Additional, optional, features of the invention are shown in FIG. 5. One feature of preferred embodiments of the price quoting system is the ability to scale the model of within the system. Users can dynamically scale the model 20, either by using the dimensions selecting tool (measured in inches, centimeters, millimeters, etc.) or by selecting a percentage (%) of the current dimensions of the object as shown by arrows 15. Certain dimensions of the part 20 such as edge 25, width 26, and height 27 can be dynamically extracted by the system and displayed to the user. Additionally, at certain stages the system will warn users that certain aspects of the model are not printable with the 3D printing process they have selected. Often this is due to excessive dimensions, thin walls, or unprintably small holes (as seen in FIG. 6).

[0036] Looking now with greater specificity to FIG. 6 exemplary actions, methods, and transactions for price quoting and order placement are shown. In a typical transaction, as shown in FIG. 6, the customer loads a file 102 on his computer 101, preferably an STL file, but other files are often used. The user than sends the file 102 to the manufacturer's input terminal or processing system 103. The system is equipped with a GUI 104. The terminal 103 is pre-loaded with protocols 105, manufacturing variables 106, and design parameters 107, such pre-loaded features are discussed in greater detail throughout the specification but may include material costs, manufacturing times, factory layout, etc.

[0037] The input terminal 103 then generates a buildable area 108 based on the design parameters and user preferences and displays them to the user in the GUI. The 3D file 102 is then displayed in the GUI and oriented 109 within the GUI and buildable area. The user may also selectively reorient 109 the model 102 according to his own preferences. The system then generates a 3D support structure 110 for the 3D file according to the orientation and size of the part and displays the support material and model to the user. In certain cases the user may then re-orient the model and the system will dynamically regenerate the 3D support structure 110 according to the new orientation of the part. The system also will conduct a series of tests 111, such as hole detection, thin wall detection, and size detection 112 which may notify the user's computer 101 of possible manufacturing issues for the part as currently oriented and generated. The customer can then choose to re-orient and modify the part to fit within typical design parameters or submit the part to an administrator 114 for a manual price quote. If no errors are detected the system can automatically generate a price quote 113 for the customer 101 who can then submit to the Administrator 114 for final approval and manufacture 115.

[0038] An exemplary price quote output page is shown in FIG. 7. Shown outputs include (but are not limited to) parts, quantity, file name and type, manufacturing process and manufacturing specifications, finish, unit price, total price, and other variables relevant to the consumer.

[0039] Accordingly, although the invention has been described by reference to certain preferred and alternative embodiments, it is not intended that the novel arrangements be limited thereby, but that modifications thereof are intended to be included as falling within the broad scope and spirit of the foregoing disclosures and the appended drawings.