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
Estimating the term…
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).
Claims21
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 first three-dimensional meta-structure sub-model;
- and
- generating, by the processor, a model of the workpiece having the first three-dimensional meta-structure sub-model by:
- converting, by the processor, the portion of the source three-dimensional model to a first finite element mesh structure, wherein the first finite element mesh structure comprises a plurality of interlinking linkages and joints that collectively form a three-dimensional manifold structure of tetrahedral, hexahedral, and/or fractal elements;
- and
- varying, by the processor, cross-sectional areas of each of the linkages and joints of the first finite element mesh structure according to a specified profile to produce the first 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, hexahedral elements, and/or fractal elements corresponding to those of the generated three-dimensional meta-structure model.
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 first three-dimensional meta-structure sub-model;
- and
- generate a model of the workpiece having the first three-dimensional meta-structure sub-model by:
- converting the portion of the source three-dimensional model to a first finite element mesh structure, wherein the first finite element mesh structure comprises a plurality of interlinking linkages and joints that collectively form a three-dimensional manifold structure of tetrahedral, hexahedral, and/or fractal elements;
- and
- varying cross-sectional areas of each of the linkages and joints of the first finite element mesh structure according to a specified profile to produce the first 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, hexahedral elements, and/or fractal elements corresponding to those of the generated three-dimensional meta-structure model.
A workpiece generated by an additive manufacturing process of a three-dimensional meta-structure model prepared by a process comprising the steps of:
- obtaining or creating, by a processor, a source three-dimensional model of the workpiece;
- obtaining or creating, by the processor, a portion of the source three-dimensional model to convert to a first three-dimensional meta-structure sub-model;
- and
- generating, by the processor, a model of the workpiece having the first three-dimensional meta-structure sub-model by:
- converting, by the processor, the portion of the source three-dimensional model to a first finite element mesh structure, wherein the first finite element mesh structure comprises a plurality of interlinking linkages and joints that collectively form a three-dimensional manifold structure of tetrahedral, hexahedral, and/or fractal elements;
- and
- varying, by the processor, cross-sectional areas of each of the linkages and joints of the first finite element mesh structure according to a specified profile to produce the first three-dimensional meta-structure sub-model.
(canceled)
Dependencies are inferred from the claim text.