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WO2024252390A1 - Procédé et système de génération de données d'objet informatique pour fabrication additive - Google Patents

Procédé et système de génération de données d'objet informatique pour fabrication additive Download PDF

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Publication number
WO2024252390A1
WO2024252390A1 PCT/IL2024/050548 IL2024050548W WO2024252390A1 WO 2024252390 A1 WO2024252390 A1 WO 2024252390A1 IL 2024050548 W IL2024050548 W IL 2024050548W WO 2024252390 A1 WO2024252390 A1 WO 2024252390A1
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WO
WIPO (PCT)
Prior art keywords
control set
tiling
different
elements
computer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/IL2024/050548
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English (en)
Inventor
Naftali Emanuel EDER
Yoav Bressler
Hila BEN YAIR
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Stratasys Ltd
Original Assignee
Stratasys Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Stratasys Ltd filed Critical Stratasys Ltd
Publication of WO2024252390A1 publication Critical patent/WO2024252390A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T17/00—Three dimensional [3D] modelling, e.g. data description of 3D objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T19/00—Manipulating 3D models or images for computer graphics
    • G06T19/20—Editing of 3D images, e.g. changing shapes or colours, aligning objects or positioning parts
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2200/00—Indexing scheme for image data processing or generation, in general
    • G06T2200/24—Indexing scheme for image data processing or generation, in general involving graphical user interfaces [GUIs]
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
    • G06T2219/00—Indexing scheme for manipulating 3D models or images for computer graphics
    • G06T2219/20—Indexing scheme for editing of 3D models
    • G06T2219/2021—Shape modification

Definitions

  • the present invention in some embodiments thereof, relates to additive manufacturing and, more particularly, but not exclusively, to a method and a system for generating computer object data for additive manufacturing.
  • AM additive manufacturing
  • Additive manufacturing entails many different approaches to the method of fabrication, including three-dimensional (3D) printing such as 3D inkjet printing.
  • 3D inkjet printing is performed by a layer by layer inkjet deposition of building materials.
  • a building material is dispensed from a dispensing head having a set of nozzles to deposit layers on a supporting structure.
  • the layers are then leveled by a leveling device, and cured or solidified.
  • WO2022/024114 describes a system for three-dimensional printing, which comprises an array of nozzles for dispensing building materials, a work tray, a jig for affixing a fabric to the work tray, and a computerized controller for operating the array of nozzles to dispense a building material on the affixed fabric.
  • An imaging system may be positioned to image a fabric placed on the work tray, and image data received from the imaging system many be processed to identify patterns on the fabric, wherein the nozzles dispense the building material at locations selected relative to the identified features.
  • a method of generating computer object data for additive manufacturing comprises: displaying a graphical user interface (GUI) having an image selection control set, a tiling selection control set, and a relief selection control set; loading image data describing a two- dimensional image selected by the image selection control set; based on a tiling pattern selected by the tiling control set, defining a plurality of discrete tiling elements each associated with a different portion of the image data.
  • GUI graphical user interface
  • the method further comprises displaying on the GUI a three- dimensional image comprising a plurality of discrete protruding elements respectively jutting out of the tiling elements of the tiling pattern, wherein each protruding element has a three- dimensional shape selected by the relief selection control set, and wherein at least a segment of each protruding element has at least one intensity level according to a respective portion of the image data.
  • the method further comprises generating computer object data describing the protruding elements, and storing the computer object data in a computer storage.
  • the method comprises identifying in the image background areas and non-background areas, wherein the discrete tiling elements tile only the non-background areas.
  • the tiling selection control set is configured to allow a user to independently select a shape for the tiling elements and a spacing between the tiling elements.
  • the tiling selection control set is configured to allow a user to independently select a size of the tiling elements.
  • the tiling selection control set is configured to allow a user to select different sizes for different tiling elements.
  • the tiling selection control set is configured to allow a user to select different spacings between different pairs of tiling elements.
  • the relief selection control set is configured to allow a user to select at least one of: (i) different heights for different protruding elements, (ii) different spacings between different pairs of protruding elements, and (iii) different cross-sectional sizes for different protruding elements.
  • the relief selection control set is configured to automatically select at least one of: (i) different heights for different protruding elements, (ii) different spacings between different pairs of protruding elements, and (iii) different cross-sectional sizes for different protruding elements.
  • the relief selection control set is configured to select a height of the protruding elements based on the respective portion of the image data.
  • the method comprises loading image data describing an additional image, wherein for at least one protruding element, intensity levels of different segments of the protruding element are based on image data of different images.
  • the GUI comprises a height map control set configured to generate or import a height map, wherein the relief selection control set is configured to select a height of the protruding elements based on the height map.
  • the GUI comprises a density map control set configured to generate or import a density map, wherein the relief selection control set is configured to select a density of the protruding elements based on the density map.
  • the GUI comprises a size map control set configured to generate or import a size map, wherein the relief selection control set is configured to select a cross-sectional size of the protruding elements based on the size map.
  • the GUI comprises a lenticularization control set, configured to allow a user to select a lenticularization scheme, wherein a shape, a color, and a transparency level of the protruding elements is selected based on the lenticularization scheme.
  • the GUI comprises a lenticularization control set, configured to allow a user to instruct the GUI to automatically select a lenticularization scheme, wherein a shape, a color, and a transparency level of the protruding elements is selected based on the lenticularization scheme.
  • the method comprises slicing the computer object data into a plurality of slices, each defined over a plurality of voxels, and storing the slices in a computer storage.
  • a method of additive manufacturing comprises executing the method as delineated above and optionally and preferably as further detailed below; loading slices generated by the method from the computer storage; assigning, for each voxel of each slice, a building material according to at least one intensity level of a respective protruding element that contains the voxel; and transmitting the plurality of slices and respective building material assignments to a controller of an additive manufacturing system for additive manufacturing of a plurality of layers respectively corresponding to the plurality of slices.
  • the computer software product comprises a computer-readable medium in which program instructions are stored, which instructions, when read by a data processor, cause the data processor to execute the method as delineated above and optionally and preferably as further detailed below.
  • a method of additive manufacturing comprises executing the method as delineated above and optionally and preferably as further detailed below; loading the computer object data from the computer storage; slicing the computer object data into a plurality of slices, each defined over a plurality of voxels; assigning, for each voxel of each slice, a building material according to at least one intensity level of a respective protruding element that contains the voxel; and transmitting the plurality of slices and respective building material assignments to a controller of an additive manufacturing system for additive manufacturing of a plurality of layers respectively corresponding to the plurality of slices.
  • the method comprises mounting a fabric on a tray of the additive manufacturing system, such that the plurality of layers are formed by the system on the fabric.
  • a system for generating computer object data for additive manufacturing comprises a display device, a computer, and a computer storage, wherein the computer comprises a processor configured to execute the method as delineated above and optionally and preferably as further detailed below.
  • Implementation of the method and/or system of embodiments of the invention can involve performing or completing selected tasks manually, automatically, or a combination thereof.
  • several selected tasks could be implemented by hardware, by software or by firmware or by a combination thereof using an operating system.
  • hardware for performing selected tasks according to embodiments of the invention could be implemented as a chip or a circuit.
  • selected tasks according to embodiments of the invention could be implemented as a plurality of software instructions being executed by a computer using any suitable operating system.
  • one or more tasks according to exemplary embodiments of method and/or system as described herein are performed by a data processor, such as a computing platform for executing a plurality of instructions.
  • the data processor includes a volatile memory for storing instructions and/or data and/or a non-volatile storage, for example, a magnetic hard-disk and/or removable media, for storing instructions and/or data.
  • a network connection is provided as well.
  • a display and/or a user input device such as a keyboard or mouse are optionally provided as well.
  • FIGs. 1A-D are schematic illustrations of an additive manufacturing system according to some embodiments of the invention.
  • FIGs. 2A-C are schematic illustrations of printing heads according to some embodiments of the present invention.
  • FIGs. 3A and 3B are schematic illustrations demonstrating coordinate transformations according to some embodiments of the present invention.
  • FIGs. 4A-F are schematic illustrations of a graphical user interface (GUI) suitable for executing a method that converts a two-dimensional image into computer object data, according to some embodiments of the present invention
  • FIGs. 5A-F are schematic illustrations of protruding elements which can be used by the method, according to some embodiments of the present invention.
  • FIG. 6 is a flowchart diagram illustrating a method suitable for generating computer object data for additive manufacturing, according to some embodiments of the present invention
  • FIGs. 7A and 7B are schematic illustrations of protruding elements characterized by different finesse values
  • FIGs. 8 A and 8B are schematic illustrations of protruding elements characterized by different severity values.
  • the present invention in some embodiments thereof, relates to additive manufacturing and, more particularly, but not exclusively, to a method and a system for generating computer object data for additive manufacturing.
  • the method and system of the present embodiments manufacture three-dimensional objects based on computer object data in a layerwise manner by forming a plurality of layers in a configured pattern corresponding to the shape of the objects.
  • the formation of the layers is optionally and preferably by printing, more preferably by inkjet printing.
  • the computer object data can be in any known format, including, without limitation, a Standard Tessellation Language (STL) or a StereoLithography Contour (SLC) format, an OBJ File format (OBJ), a 3D Manufacturing Format (3MF), Virtual Reality Modeling Language (VRML), Additive Manufacturing File (AMF) format, Drawing Exchange Format (DXF), Polygon File Format (PLY) or any other format suitable for Computer-Aided Design (CAD).
  • STL Standard Tessellation Language
  • SLC StereoLithography Contour
  • OBJ OBJ
  • 3MF Virtual Reality Modeling Language
  • AMF Additive Manufacturing File
  • DXF Drawing Exchange Format
  • PLY Polygon File Format
  • the computer object data can be a data structure including a plurality of graphic elements (e.g., a mesh of polygons, non-uniform rational basis splines, etc.).
  • the graphic elements are transformed to a grid of voxels defining the shape of the object, for example, using a slicing procedure that form a plurality of slices, each comprising a plurality of voxels describing a layer of the 3D object.
  • the term "computer object data" is used herein both in relation to the grid of voxels and in relation to the plurality of graphic elements.
  • each element of the computer object data is a voxel
  • each element of the computer object data is a graphic element, e.g., a polygon, a spline, etc.
  • object refers to a whole three-dimensional object or a part thereof.
  • Each layer can be formed by an AM apparatus which scans a two-dimensional surface and patterns it. While scanning, the apparatus visits a plurality of target locations on the two- dimensional layer or surface, and decides, for each target location or a group of target locations, whether or not the target location or group of target locations is to be occupied by building material formulation, and which type of building material formulation is to be delivered thereto. The decision is made according to a computer image of the surface.
  • the AM comprises three-dimensional printing, more preferably three-dimensional inkjet printing.
  • a building material is dispensed from a printing head having one or more arrays of nozzles to deposit building material in layers on a supporting structure.
  • the AM apparatus thus dispenses building material in target locations which are to be occupied and leaves other target locations void.
  • the apparatus typically includes a plurality of arrays of nozzles, each of which can be configured to dispense a different building material. This is typically achieved by providing the printing head with a plurality of fluid channels separated from each other, wherein each channel receives a different building material through a separate inlet and conveys it to a different array of nozzles.
  • the types of building material formulations can be categorized into two major categories: modeling material formulation and support material formulation.
  • the support material formulation serves as a supporting matrix or construction for supporting the object or object parts during the fabrication process and/or other purposes, e.g., providing hollow or porous objects.
  • Support constructions may additionally include modeling material formulation elements, e.g. for further support strength.
  • the modeling material formulation is generally a composition which is formulated for use in additive manufacturing and which is able to form a three-dimensional object on its own, without having to be mixed or combined with any other substance.
  • the final three-dimensional object is made of the modeling material formulation or a combination of modeling material formulations or modeling and support material formulations or modification thereof (e.g., following curing). All these operations are well-known to those skilled in the art of solid freeform fabrication.
  • an object is manufactured by dispensing two or more different modeling material formulations, each material formulation from a different array of nozzles (belonging to the same or different printing heads) of the AM apparatus.
  • two or more such arrays of nozzles that dispense different modeling material formulations are both located in the same printing head of the AM apparatus.
  • arrays of nozzles that dispense different modeling material formulations are located in separate printing heads, for example, a first array of nozzles dispensing a first modeling material formulation is located in a first printing head, and a second array of nozzles dispensing a second modeling material formulation is located in a second printing head.
  • an array of nozzles that dispense a modeling material formulation and an array of nozzles that dispense a support material formulation are both located in the same printing head. In some embodiments, an array of nozzles that dispense a modeling material formulation and an array of nozzles that dispense a support material formulation are located in separate printing heads.
  • System 110 comprises an additive manufacturing apparatus 114 having a dispensing unit 16 which comprises a plurality of printing heads. Each head preferably comprises one or more arrays of nozzles 122, typically mounted on an orifice plate 121, as illustrated in FIGs. 2A-C described below, through which a liquid building material formulation 124 is dispensed.
  • apparatus 114 is a three-dimensional printing apparatus, in which case the printing heads are printing heads, and the building material formulation is dispensed via inkjet technology.
  • the printing heads are printing heads
  • the building material formulation is dispensed via inkjet technology.
  • Representative examples of additive manufacturing apparatus contemplated according to various exemplary embodiments of the present invention include, without limitation, fused deposition modeling apparatus and fused material formulation deposition apparatus.
  • Each printing head is optionally and preferably fed via one or more building material formulation reservoirs which may optionally include a temperature control unit (e.g., a temperature sensor and/or a heating device), and a material formulation level sensor.
  • a temperature control unit e.g., a temperature sensor and/or a heating device
  • a material formulation level sensor e.g., a temperature sensor and/or a heating device
  • a voltage signal is applied to the printing heads to selectively deposit droplets of material formulation via the printing head nozzles, for example, as in piezoelectric inkjet printing technology.
  • Another example includes thermal inkjet printing heads. In these types of heads, there are heater elements in thermal contact with the building material formulation, for heating the building material formulation to form gas bubbles therein, upon activation of the heater elements by a voltage signal.
  • Piezoelectric and thermal printing heads are known to those skilled in the art of solid freeform fabrication.
  • the dispensing rate of the head depends on the number of nozzles, the type of nozzles and the applied voltage signal rate (frequency).
  • the overall number of dispensing nozzles or nozzle arrays is selected such that half of the dispensing nozzles are designated to dispense support material formulation and half of the dispensing nozzles are designated to dispense modeling material formulation, i.e. the number of nozzles jetting modeling material formulations is the same as the number of nozzles jetting support material formulation.
  • four printing heads 16a, 16b, 16c and 16d are illustrated. Each of heads 16a, 16b, 16c and 16d has a nozzle array.
  • heads 16a and 16b can be designated for modeling material formulation/s and heads 16c and 16d can be designated for support material formulation.
  • head 16a can dispense one modeling material formulation
  • head 16b can dispense another modeling material formulation
  • heads 16c and 16d can both dispense support material formulation.
  • heads 16c and 16d may be combined in a single head having two nozzle arrays for depositing support material formulation.
  • any one or more of the printing heads may have more than one nozzle arrays for depositing more than one material formulation, e.g. two nozzle arrays for depositing two different modeling material formulations or a modeling material formulation and a support material formulation, each formulation via a different array or number of nozzles.
  • the number of modeling material formulation printing heads (modeling heads) and the number of support material formulation printing heads (support heads) may differ.
  • the number of arrays of nozzles that dispense modeling material formulation, the number of arrays of nozzles that dispense support material formulation, and the number of nozzles in each respective array are selected such as to provide a predetermined ratio, a, between the maximal dispensing rate of the support material formulation and the maximal dispensing rate of modeling material formulation.
  • the value of the predetermined ratio, a is preferably selected to ensure that in each formed layer, the height of modeling material formulation equals the height of support material formulation. Typical values for a are from about 0.6 to about 1.5.
  • the overall dispensing rate of support material formulation is generally the same as the overall dispensing rate of the modeling material formulation when all the arrays of nozzles operate.
  • Mxmxp Sxsxq.
  • Each of the Mxm modeling arrays and Sxs support arrays can be manufactured as a separate physical unit, which can be assembled and disassembled from the group of arrays.
  • each such array optionally and preferably comprises a temperature control unit and a material formulation level sensor of its own, and receives an individually controlled voltage for its operation.
  • Apparatus 114 can further comprise a solidifying device 18 which can include any device configured to emit light, heat or the like that may cause the deposited material formulation to harden.
  • solidifying device 18 can comprise one or more radiation sources, which can be, for example, an ultraviolet or visible or infrared lamp, or other sources of electromagnetic radiation, or electron beam source, depending on the modeling material formulation being used.
  • solidifying device 18 serves for curing or solidifying the modeling material formulation.
  • apparatus 114 optionally and preferably comprises an additional radiation source 328 for solvent evaporation.
  • Radiation source 328 optionally and preferably generates infrared radiation.
  • solidifying device 18 comprises a radiation source generating ultraviolet radiation, and radiation source 328 generates infrared radiation.
  • apparatus 114 comprises cooling system 134 such as one or more fans or the like.
  • the printing head(s) and radiation source are preferably mounted in a frame or block 128 which is preferably operative to reciprocally move over a tray 12, which serves as the working surface.
  • the radiation sources are mounted in the block such that they follow in the wake of the printing heads to at least partially cure or solidify the material formulations just dispensed by the printing heads.
  • Tray 12 is positioned horizontally. According to the common conventions an X-Y-Z Cartesian coordinate system is selected such that the X-Y plane is parallel to tray 12. Tray 12 is preferably configured to move vertically (along the Z direction), typically downward.
  • apparatus 114 further comprises one or more leveling devices 32, e.g. a roller 326.
  • Leveling device 326 serves to straighten, level and/or establish a thickness of the newly formed layer prior to the formation of the successive layer thereon.
  • Leveling device 32 preferably comprises a waste collection device 136 for collecting the excess material formulation generated during leveling.
  • Waste collection device 136 may comprise any mechanism that delivers the material formulation to a waste tank or waste cartridge.
  • the printing heads of unit 16 move in a scanning direction, which is referred to herein as the X direction, and selectively dispense building material formulation in a predetermined configuration in the course of their passage over tray 12.
  • the building material formulation typically comprises one or more types of support material formulation and one or more types of modeling material formulation.
  • the passage of the printing heads of unit 16 is followed by the curing of the modeling material formulation(s) by radiation source 18.
  • an additional dispensing of building material formulation may be carried out, according to predetermined configuration.
  • the layer thus formed may be straightened by leveling device 32, which preferably follows the path of the printing heads in their forward and/or reverse movement.
  • the printing heads may move to another position along an indexing direction, referred to herein as the Y direction, and continue to build the same layer by reciprocal movement along the X direction. Alternately, the printing heads may move in the Y direction between forward and reverse movements or after more than one forward-reverse movement.
  • the series of scans performed by the printing heads to complete a single layer is referred to herein as a single scan cycle.
  • tray 12 is lowered in the Z direction to a predetermined Z level, according to the desired thickness of the layer subsequently to be printed.
  • the procedure is repeated to form three-dimensional object 112 in a layerwise manner.
  • tray 12 may be displaced in the Z direction between forward and reverse passages of the printing head of unit 16, within the layer. Such Z displacement is carried out in order to cause contact of the leveling device with the surface in one direction and prevent contact in the other direction.
  • liquid material formulation supply system 42 which comprises one or more liquid material containers or cartridges 44, and which supplies the liquid material(s) to printing heads.
  • Supply system 42 can be used in an AM system such as system 110, in which case the liquid material in each container is a building material.
  • a controller 20 controls fabrication apparatus 114 and optionally and preferably also supply system 42.
  • Controller 20 typically includes an electronic circuit configured to perform the controlling operations.
  • Controller 20 preferably communicates with a computer 24, which typically includes a display 25, and which transmits digital data pertaining to fabrication instructions based on computer object data, e.g., a CAD configuration represented on a computer readable medium in a form of a Standard Tessellation Language (STL) format or the like.
  • STL Standard Tessellation Language
  • controller 20 controls the voltage applied to each printing head or each nozzle array and the temperature of the building material formulation in the respective printing head or respective nozzle array.
  • controller 20 receives additional input from the operator, e.g., using computer 24 or using a user interface 116 communicating with controller 20.
  • User interface 116 can be of any type known in the art, such as, but not limited to, a keyboard, a touch screen and the like.
  • controller 20 can receive, as additional input, one or more building material formulation types and/or attributes, such as, but not limited to, color, characteristic distortion and/or transition temperature, viscosity, electrical property, magnetic property. Other attributes and groups of attributes are also contemplated.
  • FIGs. 1B-D illustrate a top view (FIG. IB), a side view (FIG. 1C) and an isometric view (FIG. ID) of system 10.
  • system 10 comprises a tray 12 and a plurality of inkjet printing heads 16, each having one or more arrays of nozzles with respective one or more pluralities of separated nozzles.
  • the material used for the three-dimensional printing is supplied to heads 16 by building material supply system 42, with one or more liquid material containers or cartridges (not shown), as further detailed hereinabove.
  • Tray 12 can have a shape of a disk or it can be annular. Non-round shapes are also contemplated, provided they can be rotated about a vertical axis.
  • Tray 12 and heads 16 are optionally and preferably mounted such as to allow a relative rotary motion between tray 12 and heads 16. This can be achieved by (i) configuring tray 12 to rotate about a vertical axis 14 relative to heads 16, (ii) configuring heads 16 to rotate about vertical axis 14 relative to tray 12, or (iii) configuring both tray 12 and heads 16 to rotate about vertical axis 14 but at different rotation velocities (e.g., rotation at opposite direction). While some embodiments of system 10 are described below with a particular emphasis to configuration (i) wherein the tray is a rotary tray that is configured to rotate about vertical axis 14 relative to heads 16, it is to be understood that the present application contemplates also configurations (ii) and (iii) for system 10. Any one of the embodiments of system 10 described herein can be adjusted to be applicable to any of configurations (ii) and (iii), and one of ordinary skills in the art, provided with the details described herein, would know how to make such adjustment.
  • a direction parallel to tray 12 and pointing outwardly from axis 14 is referred to as the radial direction r
  • a direction parallel to tray 12 and perpendicular to the radial direction r is referred to herein as the azimuthal direction ⁇ p
  • a direction perpendicular to tray 12 is referred to herein is the vertical direction z-
  • the radial direction r in system 10 enacts the indexing direction y in system 110, and the azimuthal direction cp enacts the scanning direction x in system 110. Therefore, the radial direction is interchangeably referred to herein as the indexing direction, and the azimuthal direction is interchangeably referred to herein as the scanning direction.
  • radial position refers to a position on or above tray 12 at a specific distance from axis 14.
  • the term refers to a position of the head which is at specific distance from axis 14.
  • the term corresponds to any point that belongs to a locus of points that is a circle whose radius is the specific distance from axis 14 and whose center is at axis 14.
  • azimuthal position refers to a position on or above tray 12 at a specific azimuthal angle relative to a predetermined reference point.
  • radial position refers to any point that belongs to a locus of points that is a straight line forming the specific azimuthal angle relative to the reference point.
  • vertical position refers to a position over a plane that intersect the vertical axis 14 at a specific point.
  • Tray 12 serves as a building platform for three-dimensional printing.
  • the working area on which one or objects are printed is typically, but not necessarily, smaller than the total area of tray 12.
  • the working area is annular.
  • the working area is shown at 26.
  • tray 12 rotates continuously in the same direction throughout the formation of object, and in some embodiments of the present invention tray reverses the direction of rotation at least once (e.g., in an oscillatory manner) during the formation of the object.
  • Tray 12 is optionally and preferably removable. Removing tray 12 can be for maintenance of system 10, or, if desired, for replacing the tray before printing a new object.
  • system 10 is provided with one or more different replacement trays (e.g., a kit of replacement trays), wherein two or more trays are designated for different types of objects (e.g., different weights) different operation modes (e.g., different rotation speeds), etc.
  • the replacement of tray 12 can be manual or automatic, as desired.
  • system 10 comprises a tray replacement device 36 configured for removing tray 12 from its position below heads 16 and replacing it by a replacement tray (not shown).
  • tray replacement device 36 is illustrated as a drive 38 with a movable arm 40 configured to pull tray 12, but other types of tray replacement devices are also contemplated.
  • FIGs. 2A-2C Exemplified embodiments for the printing head 16 are illustrated in FIGs. 2A-2C. These embodiments can be employed for any of the AM systems described above, including, without limitation, system 110 and system 10.
  • FIGs. 2A-B illustrate a printing head 16 with one (FIG. 2A) and two (FIG. 2B) nozzle arrays 22.
  • the nozzles in the array are preferably aligned linearly, along a straight line.
  • Printing head 16 is fed by a liquid material and dispenses it through the nozzle arrays 22, in response to a voltage signal applied thereto by the controller of the printing system.
  • Head 16 is fed by a liquid material which is a building material formulation.
  • the nozzle arrays are optionally and preferably can be parallel to each other.
  • all arrays of the head can be fed with the same building material formulation, or at least two arrays of the same head can be fed with different building material formulations.
  • all printing heads 16 are optionally and preferably oriented along the indexing direction with their positions along the scanning direction being offset to one another.
  • all printing heads 16 are optionally and preferably oriented radially (parallel to the radial direction) with their azimuthal positions being offset to one another.
  • the nozzle arrays of different printing heads are not parallel to each other but are rather at an angle to each other, which angle being approximately equal to the azimuthal offset between the respective heads.
  • one head can be oriented radially and positioned at azimuthal position 91, and another head can be oriented radially and positioned at azimuthal position 92.
  • the azimuthal offset between the two heads is 91-92
  • the angle between the linear nozzle arrays of the two heads is also 91-92.
  • two or more printing heads can be assembled to a block of printing heads, in which case the printing heads of the block are typically parallel to each other.
  • a block including several inkjet printing heads 16a, 16b, 16c is illustrated in FIG. 2C.
  • system 10 comprises a stabilizing structure 30 positioned below heads 16 such that tray 12 is between stabilizing structure 30 and heads 16.
  • Stabilizing structure 30 may serve for preventing or reducing vibrations of tray 12 that may occur while inkjet printing heads 16 operate.
  • stabilizing structure 30 preferably also rotates such that stabilizing structure 30 is always directly below heads 16 (with tray 12 between heads 16 and tray 12).
  • Tray 12 and/or printing heads 16 is optionally and preferably configured to move along the vertical direction z, parallel to vertical axis 14 so as to vary the vertical distance between tray 12 and printing heads 16.
  • stabilizing structure 30 preferably also moves vertically together with tray 12.
  • stabilizing structure 30 is also maintained at a fixed vertical position.
  • the vertical motion can be established by a vertical drive 28. Once a layer is completed, the vertical distance between tray 12 and heads 16 can be increased (e.g., tray 12 is lowered relative to heads 16) by a predetermined vertical step, according to the desired thickness of the layer subsequently to be printed. The procedure is repeated to form a three-dimensional object in a layerwise manner.
  • the operation of inkjet printing heads 16 and optionally and preferably also of one or more other components of system 10, e.g., the motion of tray 12, are controlled by a controller 20.
  • the controller can have an electronic circuit and a non-volatile memory medium readable by the circuit, wherein the memory medium stores program instructions which, when read by the circuit, cause the circuit to perform control operations as further detailed below.
  • Controller 20 can also communicate with a host computer 24 which transmits digital data pertaining to fabrication instructions based on computer object data, e.g., in a form of a Standard Tessellation Language (STL) or a StereoLithography Contour (SLC) format, an OBJ File format (OBJ), a 3D Manufacturing Format (3MF), Virtual Reality Modeling Language (VRML), Additive Manufacturing File (AMF) format, Drawing Exchange Format (DXF), Polygon File Format (PLY) or any other format suitable for Computer-Aided Design (CAD).
  • STL Standard Tessellation Language
  • SLC StereoLithography Contour
  • OBJ OBJ
  • 3MF Virtual Reality Modeling Language
  • AMF Additive Manufacturing File
  • DXF Drawing Exchange Format
  • PLY Polygon File Format
  • CAD Computer-Aided Design
  • the object data formats are typically structured according to a Cartesian system of coordinates.
  • computer 24 preferably executes a procedure for transforming the coordinates of each slice in the computer object data from a Cartesian system of coordinates into a polar system of coordinates.
  • Computer 24 optionally and preferably transmits the fabrication instructions in terms of the transformed system of coordinates.
  • computer 24 can transmit the fabrication instructions in terms of the original system of coordinates as provided by the computer object data, in which case the transformation of coordinates is executed by the circuit of controller 20.
  • the transformation of coordinates allows three-dimensional printing over a rotating tray.
  • non-rotary systems with a stationary tray with the printing heads typically reciprocally move above the stationary tray along straight lines.
  • the printing resolution is the same at any point over the tray, provided the dispensing rates of the heads are uniform.
  • system 10 unlike non-rotary systems, not all the nozzles of the head points cover the same distance over tray 12 during at the same time.
  • the transformation of coordinates is optionally and preferably executed so as to ensure equal amounts of excess material formulation at different radial positions.
  • Representative examples of coordinate transformations according to some embodiments of the present invention are provided in FIGs. 3A-B, showing three slices of an object (each slice corresponds to fabrication instructions of a different layer of the objects), where FIG. 3A illustrates a slice in a Cartesian system of coordinates and FIG. 3B illustrates the same slice following an application of a transformation of coordinates procedure to the respective slice.
  • controller 20 controls the voltage applied to the respective component of the system 10 based on the fabrication instructions and based on the stored program instructions as described below.
  • controller 20 controls printing heads 16 to dispense, during the rotation of tray 12, droplets of building material formulation in layers, such as to print a three-dimensional object on tray 12.
  • System 10 optionally and preferably comprises one or more solidifying devices 18, such as, but not limited to, radiation sources, which can be, for example, an ultraviolet or visible or infrared lamp, or other sources of electromagnetic radiation, or electron beam source, depending on the modeling material formulation being used.
  • Radiation source can include any type of radiation emitting device, including, without limitation, light emitting diode (LED), digital light processing (DLP) system, resistive lamp and the like.
  • Solidifying devices 18 serves for curing or solidifying the modeling material formulation. In various exemplary embodiments of the invention the operation of solidifying devices 18 is controlled by controller 20 which may activate and deactivate solidifying devices 18 and may optionally also control the amount of radiation generated by solidifying devices 18.
  • system 10 further comprises one or more leveling devices 32 which can be manufactured as a roller or a blade.
  • Leveling device 32 serves to straighten the newly formed layer prior to the formation of the successive layer thereon.
  • leveling device 32 has the shape of a conical roller positioned such that its symmetry axis 34 is tilted relative to the surface of tray 12 and its surface is parallel to the surface of the tray. This embodiment is illustrated in the side view of system 10 (FIG. 1C).
  • the conical roller can have the shape of a cone or a conical frustum.
  • the opening angle of the conical roller is preferably selected such that there is a constant ratio between the radius of the cone at any location along its axis 34 and the distance between that location and axis 14.
  • This embodiment allows roller 32 to efficiently level the layers, since while the roller rotates, any point p on the surface of the roller has a linear velocity which is proportional (e.g., the same) to the linear velocity of the tray at a point vertically beneath point p.
  • leveling device 32 is optionally and preferably controlled by controller 20 which may activate and deactivate leveling device 32 and may optionally also control its position along a vertical direction (parallel to axis 14) and/or a radial direction (parallel to tray 12 and pointing toward or away from axis 14.
  • printing heads 16 are configured to reciprocally move relative to tray along the radial direction r. These embodiments are useful when the lengths of the nozzle arrays 22 of heads 16 are shorter than the width along the radial direction of the working area 26 on tray 12.
  • the motion of heads 16 along the radial direction is optionally and preferably controlled by controller 20.
  • Some embodiments contemplate the fabrication of an object by dispensing different material formulations from different arrays of nozzles (belonging to the same or different printing head). These embodiments provide, inter alia, the ability to select material formulations from a given number of material formulations and define desired combinations of the selected material formulations and their properties.
  • the spatial locations of the deposition of each material formulation with the layer is defined, either to effect occupation of different three-dimensional spatial locations by different material formulations, or to effect occupation of substantially the same three-dimensional location or adjacent to three-dimensional locations by two or more different material formulations so as to allow post deposition spatial combination of the material formulations within the layer, thereby to form a composite material formulation at the respective location or locations.
  • Any post deposition combination or mix of modeling material formulations is contemplated. For example, once a certain material formulation is dispensed it may preserve its original properties. However, when it is dispensed simultaneously with another modeling material formulation or other dispensed material formulations which are dispensed at the same or nearby locations, a composite material formulation having a different property or properties to the dispensed material formulations may be formed.
  • the system dispenses two or more formulations to form a digital modeling material.
  • digital modeling material describes a combination of two or more materials on a pixel level or voxel level such that pixels or voxels of different material formulations are dispensed in an interlaced manner over a region, and are then hardened (e.g., cured), to form an interlaced pattern of voxels of hardened materials, the interlacing being along multiple directions.
  • Digital modeling materials may exhibit new properties that are affected by the selection of types of material formulations and/or the ratio and relative spatial distribution of two or more material formulations.
  • a "voxel" of a layer refers to a physical three-dimensional elementary volume within the layer that corresponds to a single pixel of a bitmap describing the layer.
  • the size of a voxel is approximately the size of a region that is formed by a building material, once the building material is dispensed at a location corresponding to the respective pixel, leveled, and solidified.
  • the present embodiments thus enable the deposition of a broad range of material formulation combinations, and the fabrication of an object which may consist of multiple different combinations of material formulations, in different parts of the object, according to the properties desired to characterize each part of the object.
  • system 10 and/or system 110 are configured for printing one or more objects on a fabric.
  • fabric encompasses any article of manufacture that is made at least partially of a natural or man-made fibrous material.
  • types of fabric include, but are not limited to: clothes, shoes, toys, fabric articles, carpets, cloth hats, cloth bags, socks, towels, draperies, etc.
  • the present embodiments contemplate printing on woven or non-woven fabrics.
  • woven means a structure produced when at least two sets of strands are interlaced, e.g., at right angles to each other, according to a predetermined pattern of interlacing, and such that at least one set is parallel to the axis along the lengthwise direction of the fabric, in accordance with ASTM D 123-03.
  • nonwoven means a textile structure produced by bonding or interlocking of fibers, or both, accomplished by mechanical, chemical, thermal, or solvent means and combinations in accordance with ASTM D 123-03
  • each layer of building material that is dispensed on the fabric is solidified (e.g., cured) after dispensing and without leveling the layer.
  • the height of the printed objects is below 10 cm, more preferably below 9 cm, more preferably below 8 cm, more preferably below 8 cm, more preferably below 7 cm, more preferably below 6 cm, more preferably below 5 cm, more preferably below 4 cm, more preferably below 3 cm, more preferably below 2 cm, more preferably below 1 cm.
  • the fabrication process of a three- dimensional object on the fabric includes dispensing on the fabric one or more layers of substance wherein the object is formed on the layers of the substance.
  • the substance alone or in combination with a pre-treatment process of the fabric (e.g. chemical, thermal and/or mechanical treatment) serves as an adhesive that ensure adherence between the fabric and the object.
  • the substance can in some embodiments of the present invention be a modeling material, such as, but not limited to, the modeling materials marketed by Stratasys Ltd. under the trade names VeroTM and/or VeroUltraTM (e.g. VeroUltraTM Clear), which are relatively stiff and hard, once cured. Additional materials that are contemplated include, without limitation, VeroFlexTM, and VeroEcoTM Flex marketed by Stratasys Ltd.
  • AM systems allow printing three-dimensional objects based on computer object data prepared based on three-dimensional outer shapes of the respective objects.
  • the operator selects an outer shape of the object to be manufactured, for example, by means of appropriate software, e.g., CAD software or the like, which in turns generates computer object data in the form of graphic elements (e.g., a mesh of polygons, non-uniform rational basis splines, etc.) defining a surface of the object.
  • graphic elements e.g., a mesh of polygons, non-uniform rational basis splines, etc.
  • the graphic elements are processed by a computer which employs software known as "a slicer” that transforms the graphic elements to a grid of voxels that define the internal shape of the object, and that are arranged as a plurality of slices, each comprising a plurality of voxels describing a layer of the 3D object.
  • a slicer software known as "a slicer” that transforms the graphic elements to a grid of voxels that define the internal shape of the object, and that are arranged as a plurality of slices, each comprising a plurality of voxels describing a layer of the 3D object.
  • the present embodiments thus provide a design tool that allows the end-user to select a two- dimensional image and generate in response to such a selection computer object data that can be used by an AM system to fabricate a three-dimensional object which corresponds to the selected two-dimensional image.
  • the computer object data that is generated by the design tool can be saved into a computer-readable storage medium typically in the form of one or more computer files.
  • the three-dimensional object that is described by the computer object data comprises a plurality of discrete protruding elements that collectively form a relief pattern, which is a three-dimensional representation of the imagery information contained in the selected two-dimensional image.
  • the design tool is particularly useful for fabrication of three-dimensional objects on fabric, because the protruding element structure of the fabricated object maintains the flexibility of the fabric.
  • GUI graphical user interface
  • the design tool of the present embodiments uses a graphical user interface (GUI) which is displayed by a computer, e.g., computer 24, on a display device, e.g., display device 25 of computer 24, or user interface 116.
  • GUI graphical user interface
  • the GUI provides an easy to user interface between the enduser of the AM system and the computer.
  • the GUI includes a plurality of computer-generated objects, which are referred to as "GUI controls", or in more abbreviated term "controls.”
  • GUI controls can be grouped together as sets, known as "control sets.” While a control set typically includes two or more GUI controls, a reference to a "control set” below also encompasses the specific case in which the control set includes a single GUI control.
  • Representative examples of GUI controls suitable for the present embodiments include, without limitation, a slider, a dropdown menu, a combo box, a text box, a switch button, a knob selector, and the like.
  • the GUI controls are operated by dedicated software and are responsive to physical operations performed by the user by means of devices that communicate signals to the computer.
  • Such devices can be a computer mouse, a touch screen, a keyboard or the like, and may optionally include a microphone in which case the computer is configured to execute voice- activated software.
  • the GUI can optionally and preferably display additional information, such as non-interactive text and graphics.
  • the end-user can select and activate the controls in order to initiate operations to be executed by the processor of the computer.
  • the software operating the GUI transmits activation signals to the processor, for example, by means of an I/O circuit configured to communicate signals between the GUI and the processor.
  • the activation signals can be transmitted to the processor either upon activation of the respective control, or at a later time (e.g.. upon activation of another control).
  • the controls are represented on the GUI as graphical elements that are optionally and preferably labeled in a manner that is indicative of the operation that the processor executes responsively to the activation of these controls.
  • the controls may be arranged in predefined layouts, or may be created and/or removed dynamically responsively to specific actions being taken by the end-user by means of other GUI controls.
  • a user may select a button that opens or closes another control, expands a control, displays an image, and/or switches between GUI layouts (oftentimes referred to as GUI screens, or tabs).
  • the GUI of the present embodiments receives from the end-user, by means of the GUI controls, input pertaining to one or more two-dimensional images, and optionally and preferably also to one or more characteristics of the protruding elements that are to form the relief pattern representing the imagery information in the two-dimensional image. Responsively to activation of one or more of the GUI controls, the I/O circuit of the computer communicates signals pertaining to this input from the GUI to the processor, and the processor converts those signals to computer object data describing the relief pattern. The processor saves the computer object data into a computer-readable storage medium.
  • GUI 400 comprises a plurality of control sets as further detailed below.
  • the control sets are arranged in multiple screens, denoted in FIGs. 4A-E as "screen 1," “screen 2,” “screen 3,” etc.
  • the multiple screens can be displayed simultaneously (e.g., side by side) or serially, in which case the GUI 400 may comprise one or more screen selectors 402, for allowing the end-user to instruct GUI 400 which screen to display.
  • GUI 400 comprises an image selection control set 404, illustrated in FIG. 4A.
  • image selection control set 404 is displayed in "screen 1" of GUI 400.
  • Control set 404 allows the user to select a two-dimensional image that is stored in a computer readable medium. In some embodiments of the present invention the user is allowed to select more than one two-dimensional image.
  • control set 404 comprises a text box or a browsing control 406 that allows the user to type or select the address of the image.
  • Control set 404 may comprise an image preview area 416 in which the selected image is displayed.
  • Control set 404 may optionally and preferably also comprise controls 408 allowing the user to enter the physical dimensions of the three-dimensional object to be fabricated.
  • control set 404 includes a control 410, such as, but not limited to, a drop-down menu, that allows the user to select the AM system which is to fabricate the object.
  • GUI 400 is configured to warn the user when the dimensions entered in controls 408 exceed the dimensions of the tray of the specific AM system (e.g., tray 12).
  • GUI 400 prevents the user from entering dimensions exceeding those of the tray.
  • Image selection control set 404 can also comprise a plurality of image manipulation controls, e.g., geometrical manipulation controls 412 that allow geometrical manipulation, such rotation, flipping and/or mirroring, and masking manipulation controls 414, that allow masking the image based on color or gray level or according to an input pattern or drawing.
  • geometrical manipulation controls 412 that allow geometrical manipulation, such rotation, flipping and/or mirroring
  • masking manipulation controls 414 that allow masking the image based on color or gray level or according to an input pattern or drawing.
  • the processor may optionally and preferably identify in the image background areas 418 and non-background areas 419. This can be done using any image processing technique known in the art, including, without limitation, color-based segmentation, edge-based background removal, entropy filtering, alpha matting, and the like.
  • the background can be identified by one or more specific channels of the image data.
  • image data in the form of Portable Network Graphics (PNG) contains an alpha channel, which can be used to identify the background of the image.
  • PNG Portable Network Graphics
  • the identification of the background 418 and non-background 419 areas can be done immediately upon loading the image data, or it can be in response to activation of a background identification control 417.
  • GUI 400 can also comprise a tiling selection control set 420, illustrated in FIG. 4B.
  • tiling selection control set 420 is displayed in "screen 2" of GUI 400.
  • Control set 420 allows the user to select a tiling pattern 426.
  • the processor defines a plurality of discrete tiling elements 422 each associated with a different local portion of the image data contained in the two-dimensional image.
  • all the tiling elements 422 are preferably associated respective portions of the image data contained in one of the selected two-dimensional images.
  • the tiling pattern 426 is defined only on the non-background area of the image.
  • the tiling pattern 426 substantially follows the contours of the two-dimensional image.
  • Control set 420 optionally and preferably comprises one or more tiling pattern preview areas 424 in which a preview of the selected tiling pattern 426 or a portion thereof is displayed.
  • the selection of tiling pattern 426 can be done in more than one way.
  • control set 420 comprises controls 428, 430, 432 for selecting, optionally and preferably independently, a shape (control 428) and a size or equivalently a density (control 430) for each tiling element 422, and optionally and preferably also a spacing (control 432) between adjacent tiling elements 422.
  • tiling selection control set 420 allows the user to select different sizes for different tiling elements, and/or different spacings between different pairs of tiling elements.
  • tiling selection control set 420 allows the user to load one or more maps that include information pertaining to the shape, size (or, equivalently, density), and/or spacings, of tiling elements 422 across the two-dimensional image.
  • the processor selects one or more of the characteristics of elements 422 based on the information in the respective map.
  • shapes of tiling elements 422 that can be selected by control set 420 in any of the above embodiments, include, without limitation, a polygon (for example, a triangle, a pentagon, a hexagon, an octagon, and a quadrilateral polygon, e.g., a rectangle), a circle, an ellipse and the like.
  • a polygon for example, a triangle, a pentagon, a hexagon, an octagon, and a quadrilateral polygon, e.g., a rectangle
  • the shape is convex.
  • the shape is a polygon it is optionally and preferably a regular polygon.
  • the tiling of the two-dimensional by tiling pattern 426 can be by any image processing technique known in the art.
  • the two-dimensional image is divided into super-pixels, for example, by applying a commercial image processing function such as, but not limited to, the "superpixels" function available in the Matlab® software.
  • Each super-pixel is then represented by a single point, for example, by applying a shrinking function to the super-pixel.
  • a suitable shrinking function is commercially available as one of the options within the bwmorph function of the Matlab® software.
  • a Voronoi diagram is then constructed from the obtained single points, thus tiling the two-dimensional image.
  • the advantage of this procedure is that it provides a tiling pattern that follows the contours of the two- dimensional.
  • Another suitable technique for forming a tiling pattern that follows the contours of the two-dimensional includes dividing one or more of the super-pixels into a convex polygon. This can be done by any commercial image processing function, such as, but not limited to, the "coverageDecomposition" function of the UAV Toolbox of the Matlab® software. Combinations of the above procedures are also contemplated.
  • the location of the points is perturbed in an amount that depends on one or more features of the two-dimensional image. For example a point located in a region of a small standard deviation in image values can be perturbed by a large amount.
  • the tiling of the two-dimensional by tiling pattern 426 can alternatively or additionally be based on the image data of the two-dimensional image itself.
  • a representative example of an image processing procedure suitable for this embodiment is as follows.
  • a map of values is created based on the image data. Such a map associate a specific value to each pixel of the image based on the color, hue, gray label, or contrast of the pixel, or based on distances among pixels in the image, as known in the art.
  • gradients are calculated over the map using the map values.
  • the map values and the gradients are then used to form a vector field having a plurality of discrete vectors.
  • the directions of the vectors of the field can define the gradients and the lengths of the vectors can define the map value.
  • the vector field is subjected to a geometric transform that transforms the discrete vectors into a grid of a predetermined geometry.
  • the geometry is optionally and preferably compatible with the shape of the tiling element that is selected by control set 420. For example, when the selected shape is a square the grid is a rectangular grid, when the selected shape is a triangle the grid is a triangular grid, when the selected shape is a hexagon the grid is a hexagonal grid, and so on.
  • the cells of the grid are then defined as the tiling elements 422.
  • GUI 400 can also comprise a relief selection control set 440, illustrated in FIG. 4C.
  • relief selection control set 440 is displayed in "screen 3" of GUI 400.
  • Control set 440 allows the user to select a three-dimensional shape for the protruding elements 450 that form the relief pattern 458, which, as stated, is the three-dimensional representation of the imagery information contained in the selected two-dimensional image(s).
  • Each protruding element 450 juts out of one of the tiling elements, and so the respective tiling element serves as a base of the protruding element 450.
  • Each protruding element 450 has one or more intensity levels according to a different portion of the image data (e.g., the portion that is associated with the respective tiling element).
  • the intensity level of the protruding element can be a gray level of the tiling element or a set of intensity levels that collectively define, by means of a color coordinate system, the color of the tiling element.
  • the intensity levels at different segments of the protruding element are optionally and preferably selected based on different images.
  • the intensity levels at the lower part of the protruding element can be based on one of the images, and the intensity levels at the upper part of the protruding element can be based on the other image.
  • This can be conveniently achieved by setting a predetermined vertical location threshold h, so that at all points of the protruding element having a vertical coordinate less than h, the intensity levels are based on one of the images, and at all other points of the protruding element the intensity levels are based on the other image.
  • Control set 440 can optionally and preferably include a preview area 442 in which a preview of the selected protruding element 450, and optionally and preferably also the relief pattern 458 is displayed.
  • the preview of relief pattern 458 is displayed alternatively or additionally by a different control set (e.g., in a different screen of GUI 400).
  • control set 440 selects the three-dimensional shape and size of each the protruding elements 450 automatically.
  • control set 440 can select a dome shape and uniform heights for the protruding elements 450.
  • control set 440 can include a shape selector 442, for example, in the form of a drop-down menu, that provides the user with a list of shape options for selection.
  • Representative examples of three-dimensional shapes that are suitable for the present embodiments, are illustrated in FIGs. 5A-F and include, without limitation, a cone (FIG. 5A), a dome (FIG. 5B), a hemisphere (FIG. 5C), a chamfer (FIG.
  • shape selector 442 selects a shape for the entire protruding element, and some embodiments of the present invention shape selector 442 selects a shape only for a top portion of the protruding element, wherein the other part of the protruding element is a right extrusion of the shape of the respective tiling element.
  • control set 440 can optionally and preferably include a height selector 444 (shown as a slider in the exemplified illustration) for selecting the height of each protruding element (in case in which a uniform height is employed) or the maximal allowed height for the protruding elements.
  • control set 440 also comprises a minimum height selector 446 (also shown as a slider in the exemplified illustration), for selecting the minimal height of the protruding elements.
  • all protruding elements have a height that is at least the minimal height selected by control 446 and that is at most the height selected by control 444.
  • the cross-sectional size of the protruding element 450 can be the same throughout their length, or it may be varied along at least a segment of the protruding element 450.
  • the cross-sectional size is set by the size of the respective tiling element, wherein at other parts of the protruding element the cross-sectional size is either the same as at the base, or, as illustrated in FIG. 4C, varies monotonically as a function of the distance from the base.
  • control set 440 comprises a cross-sectional size selector (not shown), which can be instead of the control 430 of control set 420.
  • the spacings between protruding elements 450 is typically set by the spacings between adjacent tiling elements. Also contemplated, are embodiments in which control set 440 comprises a spacing selector (not shown), which can be instead of the control 432 of control set 420.
  • control set 440 can select the heights in more than one way.
  • control set 440 selects the height of each individual protruding element based on the portion of the image data that is associated with the respective tiling element. For example, the selection can be based on a rule that receives, as input, the color or hue or gray level of the image data, and provides the height of the respective protruding element base on this input.
  • the processor reads the image data for each tiling element, and uses the rule to select the height of the protruding element that is to jut out of that tiling element.
  • control set 440 can comprise a height rule selector 448 which allows the user to select the rule according to which the image data is used to define the heights of the protruding elements.
  • height rule selector 448 can allow selecting between an option in which darker regions are assigned with higher protruding elements, an option in which lighter regions are assigned with higher protruding elements, an option in which red regions are assigned with higher protruding elements, an option in which green, an option in which blue regions are assigned with higher protruding elements, an option in which yellow regions are assigned with higher protruding elements, and the like.
  • height rule selector 448 includes an option in which the height of each individual protruding element is selected based on a height map.
  • the height map preferably associates each tiling element of the tiling pattern with a protruding element height, and control set 440 can set the height of each protruding element 450 based on the height value that is stored in the map for the respective tiling element.
  • the height map can be generated in response to an input by the user or automatically, or it can be loaded from a computer readable medium.
  • a representative example of a control set suitable for allowing the processor to generate a height map is provided hereinunder.
  • Relief selection control set 440 can also comprise a finesse selector 452 for allowing the user to select the finesse of the protruding elements.
  • the processor defines the tessellation resolution at curved parts of the protruding elements.
  • FIGs. 7A and 7B illustrate preview area 442 for two exemplified values entered into finesse selector 452, wherein the finesse value is higher for FIG. 7A than for FIG. 7B.
  • Relief selection control set 440 can also comprise a transparency control 454 which allows the user to select whether, and to which extent, to fabricate the protruding element using a transparent building material. Typically, but not necessarily, during AM fabrication, the selected transparency is applied only to the top part of the protruding elements.
  • transparent describes a property of a material that reflects the transmittance of light therethrough.
  • a transparent material is typically characterized as capable of transmitting at least 70 % of a light that passes therethrough, or by transmittance of at least 70 %. Transmittance of a material can be determined using methods well known in the art.
  • modeling materials suitable for fabricating transparent protruding elements include, without limitation, materials having the trade names RGD720, MED610TM, MED625FLXTM, and VeroClearTM, all commercially available from Stratasys Ltd., Israel. Additional transparent modeling materials are described in International Publication Nos. WO 2020/065654, and WO2021/014434.
  • AM of the protruding elements the transparency level of the protruding elements can be controlled by a judicial selection of the ratio between the opaque and transparent materials in a digital material that form the protruding elements.
  • Relief selection control set 440 can also comprises severity selection control 456. Typically, based on the selected severity, the processor defines the curvature of the curved parts of the protruding elements.
  • FIGs. 8 A and 8B illustrate preview area 442 for two exemplified values entered into severity selector 456, wherein the severity value is higher for FIG. 8A than for FIG. 8B.
  • GUI 400 can also comprise a lenticularization control set 460, illustrated in FIG. 4D. In the representative illustration, lenticularization control set 460 is displayed in "screen 4" of GUI 400. Control set 460 allows the user to select whether or not to apply lenticularization, and optionally and preferably also to select a lenticularization scheme.
  • Lenticularization is effected by fabricating the top part of the protruding elements as lenses (e.g., shaped as domes, or hemispheres), and coloring their bases in multiple colors such that light beams of different colors are refracted by the lenses into different directions, creating an illusion that the image that is represented by the fabricated relief pattern changes when viewed from different directions. This can be achieved by a judicious selection of at least one of the shape, color(s), and a transparency level of protruding elements 450.
  • Control set 460 may comprise a lenticularization preview area 470 providing a view of the selected image after the lenticularization is applied.
  • control set 460 comprises a preview switch 468, wherein when switch 468 is activated, preview area 470 displays the image after lenticularization, and when switch 468 is deactivated, preview area 470 displays the image before lenticularization.
  • Control set 460 preferably comprises a lenticularization activation button 462, and an indicator 464 which is highlighted upon activation of button 462.
  • the processor can select the lenticularization scheme automatically.
  • the lenticularization scheme may include at least one of the colors of the tiling elements serving as the bases of the protruding elements, the focal lengths of the lenses that form the top part of the protruding elements, and the transparency level of the protruding elements.
  • control set 460 allows the user to select the lenticularization scheme.
  • control set 460 comprises a color selector 464 by which the user can select the colors of the bases.
  • the user can select two or more colors individually, or select a single color in which case GUI 400 automatically select one or more other colors based on a predetermined coloring scheme (e.g., an inverse color, in case of a two-color scheme, or triadic colors in case of a three-color scheme).
  • a predetermined coloring scheme e.g., an inverse color, in case of a two-color scheme, or triadic colors in case of a three-color scheme.
  • GUI 400 automatically selects the colors based on the color of the tiling element itself.
  • GUI 400 splits each tiling element into two regions, wherein a first region is colored using the original color of the input two- dimensional image at the location of the tiling element, and a second region is colored using color that is the inverse of the color of the first region.
  • GUI 400 splits each tiling element into three regions, wherein a first region is colored using the original color of the input two-dimensional image at the location of the tiling element, and a second and a third regions are each colored using colors that form a triadic set with the color of the first region.
  • Control set 460 comprises a lenticularization strength selector 466 by which the user can select the strength of the lenticularization.
  • the strength selected by the user can be used by the processor to select at least one of the focal length of the lenses, the relative intensities of the colors selected by selector 464, and the transparency level of the protruding elements.
  • any of the above characteristics of the relief pattern that forms the object can be non- uniform across the object.
  • Such non-uniformity can be achieved using one or more maps that assign the respective characteristic locally over the image.
  • the processor may utilize a height map for selecting the heights
  • the processor may utilize a density map for selecting the heights
  • the processor may utilize a size map for selecting the cross-sectional sizes
  • the processor may utilize a shape map for selecting the shapes, when it is desired to make the inter-protruding element spacings non-uniform across the object the processor may utilize a spacing map for
  • the map or maps can be loaded from a computer readable storage medium or they can be generated based on user selections, for example, by means of a map generation control set.
  • a representative example of a map generation control set 480 is illustrated in FIG. 4E.
  • map generation control set 480 is displayed in "screen 5" of GUI 400.
  • Control set 480 preferably comprises an image preview area 482, which can be similar to area 416 described above, except that it optionally and preferably allows the user to mark points or regions 484 on the image.
  • Control set 480 can also comprise a local characteristic selection control 486, which in the exemplified illustration is shown as a slider but may be embodied as any other type of selector. Control 486 allows the user to select the respective characteristic separately for each individual point 484.
  • control 486 allows the user to select a height for the protruding elements separately for each individual point 484.
  • GUI 400 can have different control sets 480 for the generation of different maps, or it can display a map type selection control 488, allowing the user to select for which characteristic the map is generated.
  • the label 490 of control 486 changes accordingly. For example, in the illustrated example, a height map is selected, and therefore label 490 indicates "local height.”
  • the processor Upon activating a map creation control 492, the processor generates, based on the local values assigned to each of points 484, the respective map for all the tiling elements over the tiling pattern, e.g., using an interpolation algorithm. In case of non-numeric characteristics (for example, the shape of the tiling elements) the processor can utilize a proximity procedure to assign the local values for the respective characteristic based on the proximity to one or more of points 484.
  • the created map is displayed in image preview area 482, as exemplified in FIG. 4F.
  • FIG. 6 is a flowchart diagram illustrating a method suitable for generating computer object data for additive manufacturing, according to some embodiments of the present invention.
  • the additive manufacturing (e.g., printing) operations of the method are preferably executed by system 10 or 110.
  • the method is useful in cases in which the additive manufacturing comprises three-dimensional printing on fabric, and particularly useful in cases in which the additive manufacturing comprises three-dimensional inkjet printing on fabric.
  • Computer programs implementing the method can commonly be distributed to users on a distribution medium such as, but not limited to, a flash memory, CD-ROM, or a remote medium communicating with a local computer over the internet. From the distribution medium, the computer programs can be copied to a hard disk or a similar intermediate storage medium. The computer programs can be run by loading the computer instructions either from their distribution medium or their intermediate storage medium into the execution memory of the computer, configuring the computer to act in accordance with the method. All these operations are well- known to those skilled in the art of computer systems.
  • the method can be embodied in many forms. For example, it can be embodied on a tangible medium such as a computer for performing the method steps. It can be embodied on a computer readable medium, comprising computer readable instructions for carrying out the method steps. In can also be embodied in an electronic device having digital computer capabilities arranged to run the computer program on the tangible medium or execute the instruction on a computer readable medium.
  • the method of the present embodiments can be executed by a data processor operating an AM system (e.g., computer 24).
  • the computer object data processed by the method can be transmitted to the controller of the AM system (e.g., controller 20).
  • the processed computer object data can be transmitted in its entirety before the AM process begins, or in batches (e.g., slice by slice) wherein the AM process begins after the first batch arrives but before receiving the last batch.
  • the method of the present embodiments can alternatively be executed by the controller of the AM system (e.g., controller 20). In these embodiments, the controller receives input data and execute the method using these input data.
  • the input data can be received by the controller before the AM process begins, or in batches, wherein the AM process begins after the first batch arrives but before receiving the last batch.
  • the method begins at 600, and optionally and preferably continues to 601 at which a GUI, such as, but not limited to, GUI 400 is displayed.
  • the method proceeds to 602 at which image data describing a two-dimensional image selected by the GUI (e.g., via image selection control set 404) is loaded.
  • the method proceeds to 603 at which background and non-background areas are identified in the image as further detailed hereinabove.
  • the method proceeds to 604 at which discrete tiling elements (e.g. elements 422) are defined based on a tiling pattern (e.g., pattern 426) selected by the GUI (e.g., via tiling control set 420), as further detailed hereinabove.
  • the tiling is applied only to the non-background areas of the image.
  • the method optionally and preferably proceeds to 605 at which one or more maps defining local characteristics for the protruding elements that form the relief pattern are generated, as further detailed hereinabove.
  • the method can proceed to 606 at which the characteristics of the protruding elements are selected non-locally.
  • operations 605 and 606 are applied for different characteristics.
  • the method proceeds to 607 at which a lenticularization scheme is selected by the GUI (e.g., via lenticularization control set 460).
  • a lenticularization scheme is selected by the GUI (e.g., via lenticularization control set 460).
  • one or more of the characteristics of the protruding elements e.g., the colors of the tiling elements, the shape of the top part of the protruding elements, and the transparency of the protruding elements
  • the characteristics of the protruding elements is preferably adjusted according to the lenticularization scheme.
  • the method proceeds to 608 at which a three-dimensional image which comprises the discrete protruding elements (e.g., protruding elements 450 of relief pattern 458) protruding out of the tiling elements (e.g., elements 422) is displayed on the GUI, as further detailed hereinabove.
  • the method proceeds to 609 at which computer object data describing the protruding elements are generated and stored in a computer storage.
  • the computer object data can be in any of the aforementioned formats, and can be generated by exporting the three- dimensional image of the protruding elements as known in the art.
  • the method proceeds to 609 at which the computer object data are sliced to provide slice data describing a plurality of slices, each defined over a plurality of voxels, and describing one of the layers of the object to be manufactured.
  • the slicing operation 609 preferably assigns to each voxel of each slice, a building material according to the characteristics of the protruding elements that are to intersect the corresponding layer.
  • the slice data can be generated by the same software that operate the GUI, or it can be generated by running slicer software that is independent of the software that operate the GUI.
  • slice data that describe the slices and the respective building material assignments is transmitted to a controller of an additive manufacturing system (e.g., controller 20).
  • the controller e.g., controller 20
  • the controller which transmits control signals to the AM system to fabricate layers that respectively correspond to the slices.
  • the fabrication of the layers is on a fabric, in which case the fabric is mounted on the tray of the AM system (e.g., tray 12) before exciting operation 610.
  • compositions, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.
  • a compound or “at least one compound” may include a plurality of compounds, including mixtures thereof.
  • range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.
  • a numerical range is indicated herein, it is meant to include any cited numeral (fractional or integral) within the indicated range.
  • the phrases “ranging/ranges between” a first indicate number and a second indicate number and “ranging/ranges from” a first indicate number “to” a second indicate number are used herein interchangeably and are meant to include the first and second indicated numbers and all the fractional and integral numerals therebetween.

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Abstract

Est divulgué un procédé de génération de données d'objet informatique pour la fabrication additive, consistant : à afficher une interface utilisateur graphique (GUI) ; à charger des données d'image décrivant une image bidimensionnelle sélectionnée par la GUI ; et, en fonction d'un motif de pavage sélectionné par la GUI, à définir une pluralité d'éléments de pavage distincts associés chacun à une partie différente des données d'image. Le procédé consiste en outre à afficher sur la GUI une image tridimensionnelle comprenant une pluralité d'éléments saillants distincts s'étendant respectivement hors des éléments de pavage, chaque élément saillant ayant une forme tridimensionnelle sélectionnée par l'ensemble de commande de sélection de relief, et au moins un segment de chaque élément saillant présentant au moins un niveau d'intensité selon une partie respective des données d'image. Le procédé consiste encore à générer des données d'objet informatique décrivant les éléments saillants.
PCT/IL2024/050548 2023-06-07 2024-06-04 Procédé et système de génération de données d'objet informatique pour fabrication additive Pending WO2024252390A1 (fr)

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