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US 12,111,630 B2Granted
Method and system to generate three-dimensional meta-structure model of a workpiece
AssigneeAbemis LLC
InventorsTodd Curtis Doehring, William Joseph Nelson, II
Life of this patent
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Abstract
The exemplified methods and systems facilitate manufacturing of a new class of mechanical, loading-bearing components having optimized stress/strain three-dimensional meta-structure structures (also referred to herein as “Meshagons”) as finite-element-based 3D volumetric mesh structures. The resulting three-dimensional meta-structure structures provide high strength, ultra-light connectivity, with programmable interlinkage properties (e.g., density/porosity of linkages).
Claims17
A computer-implemented method to generate a three-dimensional meta-structure model of a workpiece for use in an additive manufacturing process, the method comprising:
- obtaining or creating, by a processor, a source three-dimensional model of a workpiece;
- defining, by the processor, a portion of the source three-dimensional model to convert to a three-dimensional meta-structure sub-model;
- and
- generating, by the processor, a model of the workpiece having the three-dimensional meta-structure sub-model by:
- generating, by the processor, for the defined portion of the source three-dimensional model, a tetrahedral mesh of varying densities parametrically formed of a plurality of tetrahedral elements, each comprising a plurality of edges and links that define four nodes, as a non-lattice mesh structure, wherein the non-lattice mesh structure comprises a plurality of interlinking linkages and joints corresponding to the plurality of edges and links that collectively form a three-dimensional manifold structure of tetrahedral elements, and
- wherein the tetrahedral mesh at each tetrahedral element provides load bearing and shear load resistant behavior similar to a corresponding solid model of the defined portion of the source three-dimensional model;
- and
- varying, by the processor, cross-sectional areas of each of the plurality of linkages and joints of the non-lattice mesh structure according to a specified non-uniform profile to produce the three-dimensional meta-structure sub-model;
- wherein the generated three-dimensional meta-structure model is used in an additive manufacturing process to produce the workpiece having a meta-structure region comprising manifolds of tetrahedral elements corresponding to those of the generated three-dimensional meta-structure model.
6 more elements
A system comprising:
- a processor;
- and
- a memory having instructions stored thereon, wherein execution of the instructions by the processor, cause the processor to:
- obtain or create a source three-dimensional model of a workpiece;
- define a portion of the source three-dimensional model to convert to a three-dimensional meta-structure sub-model;
- and
- generate a model of the workpiece having the three-dimensional meta-structure sub-model by:
- generating, by the processor, for the defined portion of the source three-dimensional model, a tetrahedral mesh of varying densities parametrically formed of a plurality of tetrahedral elements each comprising a plurality of edges and links that define four nodes, as a non-lattice mesh structure, wherein the non-lattice mesh structure comprises a plurality of interlinking linkages and joints corresponding to the plurality of edges and links that collectively form a three-dimensional manifold structure of tetrahedral elements, and
- wherein the tetrahedral mesh at each tetrahedral element provides load bearing and shear load resistant behavior similar to a corresponding solid model of the defined portion of the source three-dimensional model;
- and
- varying cross-sectional areas of each of the plurality of linkages and joints of the non-lattice mesh structure according to a specified non-uniform profile to produce the three-dimensional meta-structure sub-model;
- wherein the generated three-dimensional meta-structure model is used in an additive manufacturing process to produce the workpiece having a meta-structure region comprising manifolds of tetrahedral elements corresponding to those of the generated three-dimensional meta-structure model.
9 more elements
Dependencies are inferred from the claim text.