# US 10,769,851 B1 · Method for producing a scaled-up solid model of microscopic features of a surface

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- Number: US 10,769,851 B1
- Document ID: US10769851B1
- Status: Granted
- Kind: B1
- Application number: 15/965,959
- Filed: 2018-04-29
- Granted: 2020-09-08
- Earliest claimed: 2018-04-29
- Applicants: Dustin Kyle Nolen; Raymond George Thompson; Alex F Farris, III
- Inventors: Dustin Kyle Nolen; Raymond George Thompson; Alex F Farris, III
- Web page: https://patentgrep.com/patent/US10769851B1

## CPC

- G06T 17/205: {Re-meshing}
- B22F 10/14: by jetting of binder onto a bed of metal powder
- B22F 10/80: Data acquisition or data processing
- B29C 64/106: using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C 64/386: Data acquisition or data processing for additive manufacturing
- B29C 64/40: Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
- B33Y 40/00: Auxiliary operations or equipment, e.g. for material handling
- B33Y 50/00: Data acquisition or data processing for additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- G05B 19/4099: Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing
- G06T 15/04: Texture mapping
- G06T 17/10: Constructive solid geometry [CSG] using solid primitives, e.g. cylinders, cubes
- B33Y 10/00: Processes of additive manufacturing
- G05B 2219/35134: 3-D cad-cam
- G05B 2219/49007: Making, forming 3-D object, model, surface
- G05B 2219/49023: 3-D printing, layer of powder, add drops of binder in layer, new powder
- Y02P 10/25: Process efficiency
- G06T: IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G)
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method for producing a scaled-up solid model of microscopic features of a selected surface. A selected surface on a piece of metal exposed to friction, for example, is scanned with a profilometer along X, Y, and Z coordinates to obtain measurements of surface features. A 3-D high resolution spatial map of the surface features is made and the X, Y, and Z measurements are scaled up as desired. The spatial map is transposed into a high resolution 3-D scaled-up meshed surface. A data set of printing instructions is made from the 3-D scaled-up meshed surface acceptable for use in a 3-D printer. A solid scaled-up model of the selected surface is manufactured in the 3-D printer in any desired size using the printing instructions. The method provides a physical hand-held model of the selected surface that can be used to demonstrate accurately the effectiveness of lubrication and anti-friction products, both visually and by touch.

## Claims

### Claim 1

A method for producing a scaled-up solid model of microscopic features of a selected surface of an article, comprising:
1) measuring the shape of microscopic features on the selected surface of the article by scanning said selected surface of the article with a profilometer along X, Y, and Z coordinates;
2) making a 3-D high resolution spatial map of said microscopic surface features, scaling up the X, Y and Z measurements as desired, and adding depth to said microscopic surface features by scaling up the Z measurements to a greater extent than for the X and Y measurements;
3) creating a high resolution 3-D scaled-up computer model from the spatial map, wherein the length and the width of the computer model are at least 10 times the length and width of the selected surface and the depth of the computer model is at least 50 times the average depth of the abrasions on the selected surface; and
4) creating a data set of printing instructions from said 3-D scaled-up computer model acceptable for a 3-D printer;
5) printing a solid scaled-up model of said selected surface in any desired size using said printing instructions in the 3-D printer; and
6) taking a picture in electronic format of the selected surface, scaling the picture to the solid scaled up model of the selected surface, and printing the picture onto the solid scaled up model of the selected surface with an ink-jet printer.

### Claim 2 (depends on 1)

The method of claim 1, wherein said printing instructions are created with a slicing program.

### Claim 3 (depends on 1)

The method of claim 1, further comprising manipulating surface geometry of said 3-D scaled-up computer model to obtain desired scaled-up features and to enhance details of said 3-D scaled-up computer model.

### Claim 4 (depends on 3)

The method of claim 3, further comprising manipulating surface geometry of said 3-D scaled-up computer model to create a base for said 3-D scaled-up meshed surface.

### Claim 5

A method for producing a scaled-up solid model of microscopic features of a selected surface of an article, comprising:
1) measuring the shape of microscopic features on the selected surface of the article by scanning said selected surface of the article with a profilometer along X, Y, and Z coordinates;
2) making a 3-D high resolution spatial map of said microscopic surface features, scaling up the X, Y, and Z measurements as desired, and adding depth to said microscopic surface features by scaling up the Z measurements to a greater extent than for the X and Y measurements;
3) creating a high resolution 3-D scaled-up computer model from the spatial map, wherein the length and the width of the computer model are at least 10 times the length and width of the selected surface and the depth of the computer model is at least 50 times the average depth of the abrasions on the selected surface;
4) manipulating the surface geometry of the 3-D scaled-up computer model to obtain desired scaled-up features and to enhance details of the 3-D scaled-up computer model;
5) creating a data set of printing instructions from said 3-D scaled-up computer model acceptable for a 3-D printer;
6) printing a solid scaled-up model of said selected surface in any desired size using said printing instructions in the 3-D printer; and
7) taking a picture in electronic format of the selected surface, scaling the picture to the solid scaled up model of the selected surface, and printing the picture onto the solid scaled up model of the selected surface with an ink-jet printer.

### Claim 6 (depends on 5)

The method of claim 5, wherein said printing instructions are created with a slicing program.

### Claim 7 (depends on 5)

The method of claim 5, further comprising manipulating the surface geometry of said 3-D scaled-up computer model to create a base for said 3-D scaled-up computer model.

### Claim 8

A method for producing a scaled-up solid model of microscopic features of a selected surface of an article, comprising:
1) measuring the shape of microscopic features on the selected surface of the article by scanning said selected surface of the article with a profilometer along X, Y, and Z coordinates;
2) making a 3-D high resolution spatial map of said microscopic surface features, scaling up the X, Y, and Z measurements as desired, and adding depth to said microscopic surface features by scaling up the Z measurements to a greater extent than for the X and Y measurements;
3) creating a high resolution 3-D scaled-up computer model from the spatial map, wherein the length and the width of the computer model are at least 10 times the length and width of the selected surface and the depth of the computer model is at least 50 times the average depth of the abrasions on the selected surface;
4) manipulating the surface geometry of the 3-D scaled-up meshed surface to obtain desired scaled-up features and to enhance details of the 3-D scaled-up meshed surface, including manipulating the surface geometry of said 3-D scaled-up meshed surface to create a base for said 3-D scaled-up meshed surface;
5) creating a data set of printing instructions from said 3-D scaled-up computer model acceptable for a 3-D printer;
6) printing a solid scaled-up model of said selected surface in any desired size using said printing instructions in the 3-D printer and;
7) taking a picture in electronic format of the selected surface, scaling the picture to the solid scaled up model of the selected surface, and printing the picture onto the solid scaled up model of the selected surface with an ink jet printer.

### Claim 9 (depends on 8)

The method of claim 8, wherein said printing instructions are created with a slicing program.

### Claim 10

A scaled-up solid model of microscopic features of a selected surface of an article, produced by a method comprising:
1) measuring the shape of microscopic features on the selected surface of the article by scanning said selected surface of the article with a profilometer along X, Y, and Z coordinates;
2) making a 3-D high resolution spatial map of said microscopic surface features, scaling up the X, Y and Z measurements as desired, and adding depth to said microscopic surface features by scaling up the Z measurements to a greater extent than for the X and Y measurements;
3) creating a high resolution 3-D scaled-up computer model from the spatial map, wherein the length and the width of the computer model are at least 10 times the length and width of the selected surface and the depth of the computer model is at least 50 times the average depth of the abrasions on the selected surface;
4) creating a data set of printing instructions from said 3-D scaled-up computer model acceptable for a 3-D printer;
5) printing a solid scaled-up model of said selected surface in any desired size using said printing instructions in the 3-D printer; and
6) taking a picture in electronic format of the selected surface, scaling the picture to the solid scaled up model of the selected surface, and printing the picture onto the solid scaled up model of the selected surface with an ink-jet printer.

### Claim 11 (depends on 10)

The scaled-up solid model of claim 10, wherein said printing instructions are created with a slicing program.

### Claim 12 (depends on 10)

The scaled-up solid model of claim 10, further comprising manipulating surface geometry of said 3-D scaled-up computer model to obtain desired scaled-up features and to enhance details of said 3-D scaled-up computer model.

### Claim 13 (depends on 12)

The scaled-up solid model of claim 12, further comprising manipulating the surface geometry of said 3-D scaled-up computer model to create a base for said 3-D scaled-up computer model.

### Claim 14

A scaled-up solid model of microscopic features of a selected surface of an article, produced by a method comprising:
1) measuring the shape of microscopic features on the selected surface of the article by scanning said selected surface of the article with a profilometer along X, Y, and Z coordinates;
2) making a 3-D high resolution spatial map of said microscopic surface features, scaling up the X, Y and Z measurements as desired, and adding depth to said microscopic surface features by scaling up the Z measurements to a greater extent than for the X and Y measurements;
3) creating a high resolution 3-D scaled-up computer model from the spatial map, wherein the length and the width of the computer model are at least 10 times the length and width of the selected surface and the depth of the computer model is at least 50 times the average depth of the abrasions on the selected surface;
4) manipulating the surface geometry of the 3-D scaled-up computer model to obtain desired scaled-up features and to enhance details of the 3-D scaled-up computer model, including manipulating the surface geometry of said 3-D scaled-up computer model to create a base for said 3-D scaled-up computer model;
5) creating a data set of printing instructions from said 3-D scaled-up computer model acceptable for a 3-D printer;
6) printing a solid scaled-up model of said selected surface in any desired size using said printing instructions in the 3-D printer; and
7) taking a picture in electronic format of the selected surface, scaling the picture to the solid scaled up model of the selected surface, and printing the picture onto the solid scaled up model of the selected surface with an inkjet printer.