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  • 专利说明
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    • 专利摘要:
    A method of determining a set of points to be supported for an object to be manufactured by means of an additive manufacturing process, characterized in that it comprises a step of subdividing the object into successive layers, each layer corresponding to a thickness of material deposited during the manufacture of the object; and, for each layer, adding to a set of points to support, points to bear (Ps) on the surface of the object which make it possible to guarantee the stability of all the sub-objects (2n), a sub-object being defined as a solid resulting from the manufacture of the first i layers (Ci) of the object.
    公开号:FR3021902A1
    申请号:FR1455128
    申请日:2014-06-05
    公开日:2015-12-11
    发明作者:Sylvain Lefebvre；Jeremie Dumas；Jean Hergel
    申请人:Institut National de Recherche en Informatique et en Automatique INRIA；Universite de Lorraine；
    IPC主号:
    专利说明:

    [0001] A method of determining the points to be supported for an object manufactured by means of an additive manufacturing process; The subject matter of the invention is that of support structures for supporting an object during its manufacture by the implementation of an additive manufacturing process, the support structure and the support structure. the object being printed simultaneously. An additive manufacturing process consists of adding layers of material to achieve the object by successive deposition of material.
    [0002] Among the processes of additive manufacturing, 3D printing and, in particular, filament 3D printing, also known as FFF printing by the acronym "Fused filament manufacture", is experiencing an important growth, especially for the design phases of the process. an object before it goes into production. More specifically, a filament of material, usually a plastic, is forced through a heated and movable nozzle. During the displacement of the nozzle along a predetermined path in a horizontal plane XY, the molten filament, extruded from the nozzle, is deposited on the material of the previous layer and is welded thereon, thereby creating an additional thickness. Gradually, in successive layers, the object is manufactured.
    [0003] Filament 3D printing has a low cost price, both for the printer and for the raw material. It is also very easy to use because it only requires a few extra steps before and after the actual printing. Upstream, this involves generating a data file geometrically describing the object to be printed using a suitable CAD software, then automatically determining the paths that the printing nozzle must follow to deposit material in order to to realize this geometry. Downstream, it is to separate the object from the tray of the printer on which it was manufactured. However, a general problem of additive manufacturing processes, in particular 3D printing, stereolithography or other methods, lies in the fact that the material of a layer must necessarily be deposited on an existing surface, whether for the first layer, the plate on which the object is made or, for another layer, the layer of previous material. Consequently, it is not a priori possible to achieve directly by an additive manufacturing process, an object having overhanging portions.
    [0004] To circumvent this limitation of additive manufacturing processes, it is necessary to support the overhanging portions of the object by a suitable support, so that the material of a layer is supported and that the overhanging portion can be manufactured. Advantageously, the support is a support structure which is manufactured at the same time as the object itself and which is separated from it at the end of manufacture, in a downstream step of the manufacturing process. Thus, for a filament 3D printing method, it is appropriate, in an upstream step, following the generation of the geometry of the object to be printed by means of a CAD software and before determining the paths to be followed. the nozzle to deposit the material and realize this geometry, to develop a support structure of the object.
    [0005] Methods of constructing a support structure are known. A first method leads to the development of a robust support structure. Such a process consists firstly in extruding the surfaces to be supported from the object down to the printer tray, so as to define an extrusion volume. Then, this extrusion volume is filled using a filling pattern. The filling pattern is for example a honeycomb pattern. This pattern is predetermined and does not fit the supported object. In a second method, which also leads to the development of a support structure, robla support structure is a regular volume lattice of which only the edges in the extrusion volume are retained, the edges touching the object or located above being deleted. An additional step is to remove ridges within the extrusion volume to further simplify the support structure. The support structure is therefore always a subset of the original regular lattice. The geometry of the support structure obtained by means of these methods is therefore partly independent of the object to be printed, since the elements constituting the lattice and their positions are predetermined by the lattice pattern originally chosen. In particular, these elements can not position themselves or orient themselves locally depending on the geometry of the object to be supported which leads to a larger support structure. In addition, to ensure that such a support structure remains printable it is necessary to keep columns, which consist of a set of edges forming minimal printable structures, which limits the maximum possible reduction and complicates the suppression algorithm of the edges of the lattice. A third method, whose algorithmic details are kept secret, leads to the development of a tree support structure. Such a support structure supporting a figure is illustrated in Figure 1. A tree support structure is shown schematically in Figure 2, the end points constituting the "leaves" of the tree, being the points to bear at the surface of the object to be printed.
    [0006] A tree support structure is light. It requires only a small amount of raw material, and therefore a reduced printing time. However, this second type of method is not deterministic and leads, from the same object, to determine several possible tree support structures.
    [0007] However, some of these possible structures are not mechanically stable: they are not sufficient to support the object during its manufacture and the overhanging portions are likely to collapse during printing, leading to the manufacture an object with defects. To choose the right tree support structure, one must either perform a complex mechanical simulation, whose exact parameters are very difficult to determine, or carry out printing tests with different possible tree structures, and choose the one that led to the manufacture of an object with the least defect. Such a test / error type method is not effective in the field of 3D printing. It leads in particular to a consumption of important raw material and to high printing times. It also requires specific training for operators designing support structures. The invention therefore aims to overcome the aforementioned problems, in particular by proposing an automatic method of developing a support structure for an object to be produced by means of an additive manufacturing process, which is mechanically robust while remaining light, that is to say requiring only a reduced amount of material and a reduced printing time, the elaboration consisting, first, in defining points of the object to be supported, then, to generate A subject of the invention is a method for determining a set of points to be supported for an object to be manufactured by means of an additive manufacturing process, characterized in that it comprises a step of subdividing the object into successive layers, each layer corresponding to a thickness of material deposited during the manufacture of the object; and, for each layer, adding to a set of points to support, points to bear on the surface of the object that make it possible to guarantee the stability of all the sub-objects of the object, a sub-object being defined as a solid resulting from the manufacture of the first i layers of the object. According to particular embodiments, the support structure comprises one or more of the following characteristics, taken in isolation or in any technically possible combination: the method comprises, to guarantee the stability of any sub-object, a step consisting in verify that each sub-object placed on a horizontal base plane is in stable static equilibrium, a step during which is checked whether a disk said center of mass, the center of which corresponds to the projection of the center of mass of said sub-object and having a predefined radius, lies entirely within a base surface of said sub-object. if it is verified that the sub-object is unstable, the method includes a step of increasing the base area of said sub-object by providing at least one substantially vertical support member between a contact point of the base plane lying outside the base surface and a point to be supported on the surface of the sub-object projecting vertically outside the base plane of the sub-object and at a distance from said contact point below a distance corresponding to the radius of said center of mass disk, said point to be supported on the surface of the sub-object thus defined being added to all the points to be supported. the substantially vertical support member provided is either a vertical pillar connecting the point of contact and the point to be supported on the surface of the sub-object, or a vertical pillar and a horizontal connector bridge connecting the upper end of said vertical pillar and said point to bear on the surface of the sub-object. prior to the step of adding to a set of points to be supported, points to be supported on the surface of the object which make it possible to guarantee the stability of all the sub-objects of the object, the method comprises the steps of to, for each layer: define at least one production path of the current layer; and, for each point of a plurality of points along said path, testing a support condition, by the previous layer, of the material deposited at the point in question; and, in case of non-compliance with the support condition, add the unsupported point to all the points to be supported. in case of non-compliance with the support condition, an additional step of verifying a distance criterion, the unsupported point being added to all the points to be supported if a distance between the unsupported point and a neighboring point, belonging to the set of points to bear, is greater than a threshold distance. the or each path being of the perimeter path type, when it belongs to a perimeter portion of the current layer, or of the internal path type, when it belongs to an inner portion of the current layer, for an unsupported point of a perimeter path type path, the distance criterion used is to evaluate a curvilinear distance along said path between the unsupported point and a neighboring point, defined as the closest point among the set of points to bear that belong to the current layer; while for an unsupported point of a path of the internal path type, the distance criterion used consists in evaluating a rectilinear distance between the unsupported point and a neighboring point, then defined as the nearest point of the non-supported point among the set of points to bear that belong to the current layer and the layers below the current layer. the method comprises an additional step of determining the plurality of points to be considered during the step of testing a support condition, during which the or each path is decomposed into elementary paths extending between two successive angular points of said path, and, when the length of an elementary path is greater than a threshold length, subdivide said elementary path into as many elementary paths, said plurality of points being constituted by the ends of each of the elementary paths. the support condition tested on a point consists of calculating the fraction of the surface of a disc which covers the preceding layer, said disc being centered on the point considered and having a predefined radius, the point considered being unsupported when said fraction is less than a threshold fraction, for example 50%. the set of points to bear ensures that the filament is supported during the manufacture of the object by the implementation of an additive manufacturing process using a 3D filament printer. The invention also relates to an information recording medium, characterized in that it comprises instructions for executing a method according to the preceding method. The invention also relates to a support structure for supporting an object during its manufacture by implementing an additive manufacturing method, the support structure and the object being printed simultaneously, characterized in that it supports object in a plurality of points belonging to a set of points to support resulting from the implementation of a method of determining a set of points to support according to the above method. Preferably, the structure comprises at least one substantially vertical element between a point of contact of a base plane and a point to be supported on the surface of the object belonging to all the points to be supported, said substantially vertical element being either a vertical pillar, connecting the point of contact and the point to be supported, or a vertical pillar and a horizontal connector bridge connecting the upper end of said vertical pillar to the point to be supported. More preferably, the structure is composed of a plurality of horizontal and straight bridges, vertical pillars and inclined connectors, a lower end of a pillar resting on a bridge, on a base plane or on the surface of the object, and an upper end of a pillar carrying a connector, and a lower end of a connector resting at the upper end of a pillar and the upper end of a connector carrying a point to support the object or a point to support a bridge, each bridge being supported at least at each of its two end points, either by a pillar or by a point to support the object.
    [0008] The invention will be better understood on reading the following description of a particular embodiment, given solely for illustrative and non-limiting purposes, and with reference to the appended drawings in which: FIG. 1 is a representation graphic of an object printed with a tree support structure according to the prior art; FIG. 2 is a schematic representation of a tree support structure according to the prior art, the end points constituting the "leaves" of the tree being the points to be supported on the surface of the object to be to print ; FIG. 3 is a schematic representation of a support structure according to the invention; FIG. 4 is a block representation of a method for defining all the points to be supported on the surface of the object, whatever the nature of the final support structure supporting the points to be supported, and defined (structure according to the prior art, for example arborescent, or according to the invention); FIGS. 5a to 5c represent a monobloc object whose manufacture by an additive manufacturing process passes through the formation of intermediate sub-objects, the method of defining all the points to be supported according to the invention making it possible to support each sub-object; FIG. 6 is a schematic perspective representation of the points used in the method of FIG. 4; FIG. 7 is a block representation of a method for automatically generating a support structure according to the invention, from the data of a set of points to be supported on the surface of the object to be print, whether or not this set results from the implementation of the method of defining a set of points to be supported according to FIG. 4; FIG. 8 is an illustration of the notions of "segment" and "event" used in the method of FIG. 7; Fig. 9 is an illustration of a possible bridge; FIG. 10 is a schematic representation of a substantially vertical element, pillar or connector, of the support structure according to the invention comprising a vertical lower portion and an inclined upper portion, and FIG. 11 is a graphical representation of FIG. the object of Figure 1 with a support structure according to the invention. In the following description, the additive manufacturing process that is envisaged to implement to manufacture the object and its support structure is a 3D filament printing process. Those skilled in the art will know how to adapt the technical teaching of the present description to other types of additive manufacturing process.
    [0009] Support structure The implementation of the method according to the invention leads to the development of a clean support structure, in a final manufacturing step by means of a filament 3D printer, to be printed with the object of to support him at every moment of his impression.
    [0010] A support structure 10 is illustrated in FIG. 3. FIG. 11 shows the case of the printing of an object 2 representing a figurine, identical to that of FIG. 1, supported with the support structure according to FIG. invention. The surface of the object 2 is generally referenced by the number 4. The support structure 10 supports the object 2 in a plurality of support points Ps located on the surface 4 of the object 2. The structure of support 10 comprises a plurality of bridges 12, pillars 14 and connectors 16. A bridge 12 is a horizontal and straight component. A bridge has a length I between its two end points, and a height h above the base plane constituted by the plate of the filament 3D printer. In the following the tray of the printer is identified with a horizontal base plane XY, the normal to this plane constituting the Z axis of the dimensions. A bridge 12 is supported at least at each of its two end points. In the embodiment described here in detail, a bridge 12 is supported only at each of its two end points. However, in an alternative embodiment of the support structure, a bridge may be supported not only at each of its two end points, but also at at least one other intermediate point. A bridge is of three possible types: either it is supported at each of its two end points by pillars 14; either it is supported at one end point by a pillar 14 and the other end point corresponds to a point on the surface 4 of the object 2; or again each of its two endpoints correspond to points located on the surface 4 of the object 2. It should be noted here that a point on the surface of the object is not necessarily a point to bear on the surface of the object as defined below in relation to the methods according to the invention. This will only be the case if these points come from a stability analysis as described below. However, the algorithm for implementing the method for generating the structure can decide, if it is authorized, to anchor a bridge on the surface of the object, at any point thereof, to avoid to form a pillar. The bridges of the second and third types are referred to as "connector bridges" in what follows. They are indicated by the reference 12C, as for example in FIG. 5. Unless explicitly stated, a bridge 12 is a bridge of the first type. In a variant, the structure comprises only bridges of the first type. A pillar 14 is oriented vertically. It is supported by its lower end, either directly on a bridge 12, or directly on the base plane, or directly on the surface 4 of the object 2. A pillar 14 supports, indirectly, through a connector 16, either an end point Pe of a bridge 12, or a point to support Ps at the surface 4 of the object 2. As shown in FIG. 7, a connector forms an angle ao less than an angle maximum aomax and has a height ho less than a height ho ,. In general, these two parameters are constrained simultaneously so that a connector 16 does not exceed a maximum inclination angle which may have a low mechanical strength and be difficult to print. It should be noted that a pillar 14 can have zero height, so that a bridge 12 located higher rests directly on a bridge 12 located lower, or a connector 16 is supported by its lower end directly on a bridge. A connector 16 may also have a zero height, so that a pillar 14 supports a point which is located directly above the point of the bridge on which the pillar supports. As represented in FIG. 10, a bridge 12 directly supports at least n pillars 14 (a pillar that can have a zero height), that is to say supports n points to be supported among the end points of bridges 12 situated more or points to bear Ps on the surface 4 of the object 2. The advantage of a bridge 12 is to reduce the number of points to support P, substituting the n points it supports, the p pillars 14 which support it, it is desirable that the integer n be greater than the integer p. In the embodiment described here in detail, p being equal to 2, it is desirable for n to be greater than or equal to 3. This constraint is implemented by a gain function G adapted in the method of generating the support structure, which will be described below.
    [0011] In an alternative embodiment, if the pillars are too high, it is preferable to add an intermediate stiffening bridge. Such a bridge supports a vertical pillar and is supported by two vertical pillars. This makes it possible to stiffen the structure and to avoid buckling phenomena of a pillar that is too high.
    [0012] Bridges 12 and connector bridges 12C are, in top view, that is to say in projection in a horizontal plane XY corresponding to the base plane, distributed in d directions. By direction, we mean the two possible directions along a line. Preferably, the directions are deduced from each other by rotations of Tr / d. In the case of using a 3D filament printer, a bridge 12 is constituted by at least one filament printed between two end points to be supported constituted by the upper ends of the two pillars 14 supporting the bridge 12 in question. Similarly, a connector bridge 12C is constituted by at least one filament printed between two points to be supported constituted by a point to support Ps of the surface 4 of the object 2 and the upper end of the pillar 14 which supports it.
    [0013] It has been found that it is possible to use a filament 3D printer to stretch a filament of material over a vacuum between two support points whose distance is less than a maximum range Dmax of a few centimeters. The hot filament is extruded to weld at both support points forming a chain between these two points. As the filament cools, the filament material retracts to form a substantially horizontal bridge. Thus, in the embodiment currently envisaged, a bridge 12 (respectively 12C) consists of two successive layers. Each layer has a thickness of 0.4 mm. It consists of two filaments arranged side by side, at a distance of 0.8 mm from each other, a distance that corresponds substantially to the diameter of the filament used. The bridges 12 (respectively 12C) thus formed have sufficient mechanical properties to serve as an elementary component of a support structure of an object. It has thus been found that a bridge 12 (respectively 12C) can withstand several grams alone. However, the objects to be printed often use less than 10 m of filament (for a filament 1.75 mm in diameter, this represents an object of about 25 g) and are supported by a support structure comprising several bridges. The object is therefore properly supported mechanically. Each vertical element, pillar 14 or connector 16, preferably has a cross section in the form of a cross. Such a section allows both a reduced consumption of raw material and therefore a fast printing, while providing good rigidity. Of course, other choices of section are possible.
    [0014] The support structure 10 of the object 2 of FIG. 3 weighs 0.5 g, while the object itself weighs about 10 g. Method for Defining the Set of Contact Points to Be Supported A method for defining an assembly E0 of points to be supported on the surface of an object to be manufactured will now be described. This method of definition, which constitutes a first aspect of the invention, is independent of the method of generating the support structure, which will be used subsequently, in particular the generation method 200 described below and constituting a second aspect of the invention. Thus, the implementation of the method 100 leads to the definition of a set E0 of points to bear Ps on the surface 4 of the object 2. The set E0 groups the points of the surface 4 of the object 2 to be supported by the support structure 10. Incidentally, a pillar 14 of the support structure 10 can bear either on a bridge 12, or on the XY base plane, or on the surface 4 of the object 2 itself , the set of points of contact between the support structure 10 and the object 2 comprises not only the set E0 of the points to support Ps, but also the points of the surface 4 of the object 2 which are supported by some pillars 14 of the support structure 10.
    [0015] Advantageously, the method 100 makes it possible to define an assembly E0 which, by the implementation of a first series of steps 102, makes it possible to support the filament during printing, and which, by a second series of steps 104, ensures the stability of the object at each moment of printing. For this, the method 100 comprises a first series of steps of determining points to support Ps which together allow to support the filament during printing. In a step 112, the object 2 to be printed is subdivided into horizontal layers, each layer C corresponding to the thickness of material deposited at each passage of the nozzle of the filament 3D printer. At this stage, only object 2 is considered. The index i corresponds to one step along the Z axis of the ratings. The following steps are iterated for each layer C 1, i.e., on the integer i. It is not recalled at each step to not weigh down the ratings. In step 114, for each layer C ,, the paths ch, followed by the nozzle to print the layer in question are determined. The paths are either of the perimeter path type, when they belong to the edge forming the perimeter of the layer C ,, or of the internal path type, when they belong to the interior of the layer C 1, ie say at layer C, from which was removed the edge forming its perimeter. At step 116, each path ch, is decomposed into elementary paths sheik, each segment extending between two successive angular points of the path, i.e. two points where there is a significant change in the direction of the path. moving the nozzle. When the length of an elementary path is greater than a threshold length lo (of 5 mm for example), it is subdivided into as many elementary segments. The threshold length lo constitutes an adjustable parameter of the process. In step 118, the end points of the sheikh elementary paths are placed in a first list L1. The list L1 is ordered according to the path of the nozzle to print the current layer C. Step 120 consists in verifying that each point P1 of the first list L1 is supported by the layer CH1, situated immediately below the current layer C1. This verification consists of calculating the fraction of the surface of a disk D (P1) supported by the layer CH1, this disc being centered on the point P1 and having a predefined radius, corresponding for example to the diameter of the nozzle (0.4 mm in the practical implementation of the present process). If more than a threshold percentage (predefined and adjustable), for example equal to 50%, of the surface of the disk D (P1) is not supported by the previous layer, the point P1 is considered to be a non-point. supported. It is entered in a second list L2, which is ordered according to the path of the nozzle to print the layer C. In step 122, the second list L2 is traveled. If a point P2 of the list L2 belongs to a path ch, of the perimeter type, it is selected in the set E0 of the points to bear Ps, if the distance between the point P2 and a neighboring point PV (defined as the point of the set E0 belonging to the layer C, the closest to the point P2 considered) is greater than a threshold distance T, the distances here being curvilinear distances evaluated along the path considered. On the other hand, if the point P2 of the list L2 belongs to a path ch, of the internal type, the non-supported point P2 is selected in the set E0 of the points to bear, if the distance between the point P2 and a neighboring point PV (defined then as the point of the set E0 belonging to the layer C, considered or to a lower layer, Ci with j <i, the closest to the point P2 considered) is greater than the threshold distance distances being in this second alternative of rectilinear distances. At the end of step 122, the set E0 of the points to be supported is determined.
    [0016] Thus, at the end of this first series of steps 102, a set of points to be supported is defined which makes it possible to guarantee the maintenance of the filament during the printing of the object. Alternatively, other series of steps could be implemented to determine such a set of points to support ensuring the maintenance of the filament during printing. The method 100 is advantageously continued by a second series of steps 104 consisting of completing a set of points to be supported, with additional points located on the surface 4 of the object 2, so as to guarantee the stability of the object 2 at every moment of his impression. The set of points to bear considered at the beginning of this second series of steps is advantageously the set E0 points to support defined in the first series of steps presented above.
    [0017] Layer-by-layer printing of a monobloc object 2 often involves the printing of sub-objects 2, intermediate which are independent at a certain height and which are welded together at a higher height. This is illustrated in FIG. 5 by a domed object 2, whose four jamb-shaped sub-objects 2 are connected to each other only at the moment of printing the vault key. Each sub-object 2 can be unstable before being assembled to another sub-object to form the object 2. A sub-object 2 can therefore possibly fall or switch, leading to a faulty print. This problem is a generic problem of additive manufacturing. It is particularly present in stereolithography processes. The implementation of the method performs an analysis for evaluating, at each layer C, of material added by the filament 3D printer, the stability of at least one sub-object 2, printed so far. It should be emphasized that the method does not take into account the possibility of using a bonding agent in order to glue the object to be printed on the tray of the printer. But the use of such a glue can only improve the stability of any sub-objects of the object. In addition, it is assumed that said sub-object is rigid. Check that a sub-object 2, placed on the basic plane XY is in stable static equilibrium, consists in checking if its center of mass C ',,, is projected vertically in a point Mn situated inside a base area B, sub-object 2 ,. The base surface B, of a sub-object 2, is the smallest convex polygonal surface having all the points of the sub-object 2, in contact with the basic plane XY. The following steps aim at increasing the base area B, of an unstable sub-object 2n, by the addition of a vertical pillar 14 between a new contact point Pc on the base plane XY and a new point to be supported. Ps at surface 4 of sub-object 2 ,. The mechanically stable system is then constituted by the sub-object 2, and the vertical pillar 14 added. In the present embodiment, only the possibility of adding a vertical pillar 14 between a contact point Pc on the XY base plane and a point to support Ps on the surface of the sub-object is considered. However, when determining the support structure to be printed, as will be described below in detail, this point to support Ps may be supported not by a single vertical pillar 14, but by a group of pillars 14 and 12. But, the set of points of contact of this group of pillars and bridges on the XY base plane leads to an increase of the base area B which is larger and which includes the increase of the surface area. base B generated by the single point of contact Pc. This follows from the fact that the base surface is by definition convex and that the bridges are always supported at each of their two ends by pillars, so that if the point to be supported Ps is supported via a bridge, a support pillar of this bridge will be outside the base surface determined by considering only the vertical projection of the point to be supported P. Thus, during printing, the support structure can only improve the stability of the sub-object relative to the use of a single vertical pillar. In step 124, for the current layer C, for the or each sub-object 2 ,, the projection Mn on the base plane XY of its center of mass Cm, n is determined.
    [0018] Advantageously, this is done taking into account the printing paths ch, and not the single volume delimited by the surface 4 of the sub-object 2n. Indeed, the interior of the sub-object can be full, made of honeycombs, etc., which influences the position of the center of mass Cm, n and therefore that of the point Mn on the XY base plane. The static equilibrium of a sub-object can be disturbed by the forces applied by the nozzle during the deposition of material. For this reason, it is checked whether a disk D (M,), centered on the point Mn and having a predefined radius R, lies entirely inside the base surface B, the sub-object 2 ,. The radius R of the disk is for example equal to 3 mm. In an alternative embodiment the radius of the disk depends on the mass distribution around the center of mass and the height between the center of mass and the plate, so as to take into account a lever arm effect. In step 126, for the iteration on layer C 1, an initial base area B n, 0 (FIG. 6) is enlarged. When analyzing the first layer C1, the initial base area Bn, 0 is initialized with the minimum convex polygon having all the contact points Pc of the first layer C1 of the sub-object 2n on the XY base plane.
    [0019] At each iteration, the initial basal area Bn, 0 is first enlarged taking into account, as an additional point of contact, the projection on the base plane XY of each point to bear Ps of the set E0 and which belongs to the layer C. An increased base area 13 ,,, is obtained.
    [0020] At step 128 is then checked whether the disk D (Mn) is entirely within the increased base area Bn, 0. If so, the process proceeds to the next layer C ,,, and resumes in step 114. For the next iteration, the initial basal area Bn, 0 takes the value of the augmented base area B n, 1 .
    [0021] If not, an additional point on the surface of the sub-object shall be added to the set E0 of the points to be supported. In a particular embodiment, an additional point is selected as follows. In step 130, a third list L3 of candidate contact points PCp is determined. A candidate contact point of this third list is a point of the base plane corresponding to a point PSp of the surface 4 of the sub-object 2n which projects out of the augmented base area Bn, 1 (this point does not belong to necessarily at layer C, current). It should be noted that the surface of the object is sampled or pixelated so that the list L3 has a finite number of points.
    [0022] By building a vertical pillar from this candidate point PCp, to support this point PSp of the surface of the subobject 2n, there is a priori possibility of increasing the base area Bn of the subobject supported by this pillar and to make the corresponding system stable. In fact, a circle D (PCp) of PCSpq secondary candidate points around each PCp candidate point is considered. This circle has a radius equal to the radius R of the disk D (Mn), so as to ensure that the base surface Bn can be modified to encompass the entire disk D (Mn). In step 132, for each secondary candidate point PCSpq of the circle D (PCp) is determined the percentage of the disk surface D (Mn) that would be encompassed by the variation of the increased base area Bn, 1, if this point secondary candidate PCSpq was a point of contact for the system. The PCSpq points associated with the various PCp candidate points of the list L3 are placed in a fourth list L4 in descending order of the percentage thus calculated. Here again the perimeter of the disc is sampled or pixelated so that the list L4 has a finite number of points.
    [0023] Then, in step 134, by successive iterations on points PCSpq of the list L4, the augmented base area Bill is enlarged to obtain an enlarged base area Bn, 2. At each integration of a new secondary candidate point PCSpq, the base area is recalculated and it is checked whether the entire disk D (Mn) is within the recalculated base area. This process is stopped when the entire disk D (Mn) is within the recalculated base area, which is then stored as the enlarged base area Bn, 2. The list L4 is then truncated so as to retain only the secondary candidate points used. Because of the order of taking into account the points in the list L4, it is possible that points added in the first iterations do not finally contribute to the enlarged base area Bn, 2, that is to say not are not on the perimeter of this modified base surface, but inside it. These points are, in step 136, removed from the points used for the increase of the base area. A fifth list L5 of points is then obtained from the truncated list L4. The enlarged base area Bn, 2 constitutes the initial base area Bn, 0 for the next iteration of the process on the next layer C41. The list L5, consisting of the contact points on the XY base plane, is used in step 138 to determine the new points Ps of the surface 4 of the sub-object 2n to be supported to guarantee the stability during the printing . For this, at step 138, for each PCSpq point of the list L5, is calculated the intersection point between a vertical from the point PCSpq considered and the surface of the sub-object 2n restricted to the current layer C, and lower layers, C, with j <i.
    [0024] When it exists, this intersection point PSq is added to the set E0 as a new point to support. If the vertical does not intersect the surface of the sub-object 2n restricted to the current layer C ,,, a connector bridge 12C is added in a set of bridge bridges connector. This connector bridge 12C connects the upper end of the vertical end of the PCSpq considered point (end lying at the level of the layer C, current) and a point P'Sq of the surface of the sub-object 2n whose vertical projection is located inside the circle D (PCp) on the perimeter of which is the point PCSpq considered. Then the method 100 loops to analyze the next layer C ,,, of the object. At the end of the process, there is obtained a set E0 of points to support Ps on the surface of the object and a set BO of bridges, having connector bridges 12C.
    [0025] A method of generating a support structure The method of generating a support structure constituting a second aspect of the present invention takes as input a set of points to bear. This set is advantageously defined by the implementation of the method presented above, but can be defined by any of the methods of the state of the art. The method 200 for generating a support structure 10 of the object 2 thus starts with a step 210 of initialization of a set E of the points to bear P, which results from the meeting of the set E0 of the points to to support Ps at the surface 4 of the object 2, obtained at the output of the method 100, and the free PE end points of each connector bridge 12C of the set BO, obtained at the output of the method 100. More generally, the point The free PE end of a bridge is an endpoint that is not yet supported. It is therefore a point constituting a degree of freedom in the construction of the support structure: it can be moved by stretching the corresponding bridge to get a fulcrum located in its vertical alignment on a bridge located more down, or optionally on a portion of the surface of the object in its vertical alignment. The method continues with a loop 212 on a set of scan directions. A scanning direction in the XY plane is perpendicular to the corresponding scanning plane which is therefore vertical. Preferably, the method takes into account a number of scan directions. In the embodiment described here in detail, these directions are angularly separated from Tr / d. As a variant, the set of directions results from a step of geometric analysis of the object 2 to determine whether it has privileged directions.
    [0026] For reasons of symmetry, it is not necessary to consider the directions beyond Tr. The direction d = 0 corresponds to the direction in the X direction. For the sake of clarity, the following is described in detail below: case of the iteration where the scanning direction corresponds to the X axis (d = 0). In step 216, the method continues by creating segments from each point to bear P of the set E and the current scanning direction, in this case the direction X. As shown in FIG. 8, a segment of a first type Seg1 is generated from each point of the set E which is of the point type to bear Ps at the surface 4 of the object 2. It is a segment of length 2 x I'x, parallel to the current scanning direction and centered on the point to be supported P.
    [0027] A segment of a first type Seg1 is also generated from each point of the set E which is of the type a free end point PE of a bridge 12, such as the point PE, of the bridge 121. Here again it is a segment of length 2 x I'x, parallel to the current scanning direction and centered on the considered free endpoint PE of the bridge 12. A segment of a second type Seg2 is generated from of each point of the set E which is a free end point PE of a bridge 12, such as the point PE, of the bridge 121. This is a segment parallel to the direction of the bridge 121 and extending away from it, beyond the free end point PE ,.
    [0028] If the two end points of the bridge 12 are free, the length of a segment Seg2 is such that the sum of the minimum length of the bridge 12 and the length of the segment Seg2 is equal to the maximum operating range Dmax of A bridge. It should be noted that the minimum length of a bridge 12 is the distance, evaluated according to the direction of the bridge, separating the n points supported by this bridge.
    [0029] If only one endpoint is free, the length of the segment Seg2 is such that the sum of the length of the bridge 12 and the length of the segment Seg2 is equal to the maximum range Dmax of manufacture of a bridge. The segments constructed in this step are stored in a set S. In step 218, the method continues by creating events e associated with the segments of the set S. An event is either a point P of the set E (point Ps on the surface of the object or free end point PE of a bridge, possibly of the bridge bridge type), ie a P1 intersection between two segments of the set S. The list of events is denoted Q It is ordered according to the increasing value of the coordinate of the events e according to the scanning direction, in this case according to the abscissa X of the events. Then, the method enters a loop 220 relating to the events e of the list Q. At each iteration of the loop 220, the current event e is removed from the list Q (step 222), so that the process proceeds from loop 220 when the list Q is empty.
    [0030] In step 224, the scanning plane is placed on the event e. Then, all the points P associated with segments of the set S which cut (at points of intersection PI) the scanning plane are placed in a list PP (e). These are the segments of the list S which, according to the scanning direction, begin before the event e and ends after the event e. In particular, the segments resulting from the current event e are selected. A list PP (e) is obtained for each event e of the list Q. Each list PP (e) is ordered according to the coordinate Y of the scanning plane. Then, in step 226, for each PP (e) list, all PPS (e) sub-lists of points are considered. If the list PP (e) corresponds to the set (P0, ... Pi, ... Pn), then all sub-lists (Pj, ..., Pk) such as distance, according to the direction Y, between points Pj and Pk is less than the maximum range Dmax- Each sub-list PPS (e) is then evaluated to determine whether it is possible to build a bridge that would support all or part of the points P of this sub-list PPS (e) = (Pj, ..., Pk), by as many pillars 14 and connectors 16, from this possible bridge. In step 228, the height of each point of the current sub-list PPS (e) = (Pj, ..., Pk) is decreased by a predetermined minimum height 1-4 corresponding to the minimum height of a connector 16. A list of possible heights (hj, ..., hk) for the sub-list PPS (e) = (Pj, ..., Pk) is thus obtained.
    [0031] Then, for each height of this list of heights, is determined a possible bridge PPS (e, h) to support the points of the list PPS (e); ie points whose height is greater than the current height and which can be reached by a connector. In step 230, it is verified that a possible bridge and the possible bridges 14 and connectors 16 that it is likely to bear do not collide with the object 2 to be printed. The evaluation continues with a step 232 of calculating a gain function G making it possible to quantify the interest of replacing n vertical pillars supporting the points of the PPS list (e, h) and based on the XY base plane. by a bridge 14 supporting n shorter vertical pillars supporting the points of the list PPS (e, h), the bridge itself bearing on the XY base plane by at least two vertical pillars. In the embodiment currently envisaged, and as shown in FIG. 9, a possible bridge of length I and height h, supporting n elements and supported by two vertical pillars, has a gain G of: G = (n-2 xh-I With such a gain function, only the case of a possible bridge supporting more than two pillars is favorable. In an alternative embodiment, to take into account the case where one end of a possible bridge is located above the object, the exact length of the vertical pillar connecting this end to the object is used in place of the height the bridge measured in relation to the base plane. Thus, the gain function becomes: G = nxh-hl -h2 -I where h1 and h2 are the exact heights of the pillars at the ends of the possible bridge. It should be noted that lowering the height h of a possible bridge PPS (e, h) reduces its gain G, so that a possible bridge has a maximum gain at the distance hn- ', below the lowest point it supports. Finally, only the possible PPS (e, h) bridges whose gain is positive (G> 0) are retained. Then in step 234, a score function F is calculated for each possible bridge PPS (e, h) of positive gain.
    [0032] In the presently envisaged embodiment, this score function is defined by: F = G-nx I'x where I'x is the greatest of the heights among the heights of the various vertical pillars bearing on the possible bridge PPS (e h) considered, as shown in FIG. 9. Such a score function F penalizes an inhomogeneous distribution of the heights of the vertical elements bearing on the possible bridge PPS (e, h) considered. Once all the events of the list Q have been considered, at step 236, the possible positive gain PPS (e, h) bridge having the highest F score (possibly a negative score) among the possible possible bridges when scanning in the current direction, is selected as the best possible BPP bridge for this iteration of the scan. In step 238, the points P of the PPS list (e, h) that correspond to the best BPP possible bridge are "frozen" and a description file F10 of the support structure 10 is updated. For a point P of the PPS list (e, h) corresponding to the intersection of a segment of the first type Seg 1 with the scanning plane, an additional vertical pillar 14 is added in the file F10. This vertical pillar 14 connects the point of the best possible bridge (of height h) corresponding to the intersection, in the XY plane, between segment Segl and the scanning plane placed in e. This pillar 14 optionally supports at its end an inclined connector 16 to cover the distance between the intersection, in the XY plane, between the segment Seg 1 and the scanning plane placed at e and the point of the PPS list (e, h ) corresponding to this segment Seg 1.
    [0033] For a point P of the PPS list (e, h) corresponding to a segment of the second type Seg2, the bridge 12 corresponding to this segment Seg2 is extended to the vertical of the point of intersection, in the XY plane, of the segment Seg2 and the scanning plane placed in e. A vertical pillar is then provided to connect the point of the best BPP possible bridge corresponding to this intersection and the end point of the bridge 12 moved to the vertical of this point of intersection. If this Seg2 segment corresponds to a bridge 12 whose other end is a free endpoint, the length of the segment associated with this other end is recalculated to meet the constraint on the maximum range Dmax of a bridge.
    [0034] Thus a connector 16 appears as a means for releasing the constraint on the distance, evaluated in the XY plane, between a point to support and a bridge to support this point, this bridge belonging to the scanning plane. Consequently, it is not necessary for a point to be supported to be strictly vertical to a bridge enabling it to be supported. It is enough that it is not too far for a connector 16 can connect this point to a vertical pillar from this bridge. The F10 file of the structure is thus updated with the information available for the various "frozen" points. In step 240, the different points P supported by the best bridge BPP = PS (e, h) are removed from the set E points to bear. On the other hand, the end points of the best BPP bridge are added to the set E. These free end points correspond to the minimum length 'min of the best selected BPP bridge considering the n elements it supports. The process is iterated with a new scanning direction. When an iteration of the scan does not make it possible to determine a better possible bridge, the method 200 proceeds to step 250. The remaining points of the set E are then supported by pillars 14 extended to the base plane XY, or, where appropriate, to the portion of the surface of the object below, on which they rest. The F10 structure description file is updated. Optionally, a constraint on the maximum height of a pillar 14 may be implemented. If this height is exceeded, the pillar is reduced and is supported by an additional bridge. Then, the description file of the support structure and that of the object are merged to allow the generation of a command file allowing the printing of the object and the support structure by a filament 3D printer.
    [0035] It should be noted that the gain function can be modified to discourage the formation of bridges whose ends are above the surface of the object to be manufactured.
    [0036] The functions of gain and score allow a great flexibility and a control of the structure. In addition, artificial events can be added to the Q list to guide the shape of the structure.
    权利要求:
    Claims (14)
    [0001]
    CLAIMS 1. A method of determining a set of points to be supported for an object to be manufactured by means of an additive manufacturing process, characterized in that it comprises a step of subdividing (112) the layered object. (C,) successive, each layer corresponding to a thickness of material deposited during the manufacture of the object (2); and, for each layer, adding to a set (E0) of points to bear, points to bear on the surface of the object (2) which make it possible to guarantee the stability of all the sub-objects (2n) of the object (2), a sub-object being defined as a solid resulting from the manufacture of i first layers (C,) of the object.
    [0002]
    2. A method according to claim 1, comprising, to guarantee the stability of any sub-object (2), a step of verifying that each sub-object placed on a horizontal base plane is in stable static equilibrium, step during which is checked whether a center-of-mass disk (D (Mn)), whose center corresponds to the projection of the center of mass (Cm, n) of said sub-object and having a predefined radius (R), located entirely within a base surface (Bn) of said sub-object.
    [0003]
    The method of claim 2, wherein, if it is verified that the sub-object (2n) is unstable, the method includes a step of increasing the base area (Bn) of said sub-object by providing for at least one substantially vertical support member (14) between a point of contact (Pc) of the base plane lying outside the base surface and a point to be supported (Ps) on the surface of the sub-object (2n ) projecting vertically outside the base plane of the sub-object and being at a distance from said lower contact point to a distance corresponding to the radius (R) of said center of mass disk, said point to be supported (Ps) on the surface of the sub-object thus defined being added to the set (E0) points to support.
    [0004]
    4. A method according to claim 3, wherein the substantially vertical support member provided is either a vertical pillar (14) connecting the point of contact and the point to be supported on the surface of the sub-object, or a vertical pillar ( 14) and a horizontal connector bridge (12C) connecting the upper end of said vertical pillar (14) and said point to be supported on the surface of the sub-object.
    [0005]
    5.- Method according to any one of claims 1 to 4, wherein, prior to the step of adding to a set (E0) points to bear, points to bear on the surface of the object (2 ) which make it possible to guarantee the stability of all the sub-objects (2,) of the object (2), the method comprises the steps of, for each layer: defining (114) at least one path (Ch,) manufacturing the current layer; and for each point of a plurality of points along said path, testing (120) a support condition, by the preceding layer, of the material deposited at the point in question; and, in case of non-compliance with the support condition, - add the unsupported point to the set (E0) of the points to be supported.
    [0006]
    6. A method according to claim 5, comprising, in case of non-compliance with the support condition, an additional step (122) for verifying a distance criterion, the unsupported point being added to all of the points to bear if a distance between the unsupported point and a neighboring point, belonging to all the points to bear, is greater than a threshold distance (i-).
    [0007]
    7. A method according to claim 5 or claim 6, wherein, the or each path (chi) being of the perimeter path type, when it belongs to a perimeter portion of the current layer (C,), or the internal path type, when it belongs to an inner portion of the current layer (C,), for an unsupported point of a path of the perimeter path type, the distance criterion used is to evaluate a curvilinear distance along said path between the unsupported point (P2m) and a neighbor point (PVm), defined as the closest point among the set (E0) of points to bear which belong to the current layer (C,); while for an unsupported point of a path of the internal path type, the distance criterion used consists in evaluating a rectilinear distance between the unsupported point (P2m) and a neighboring point (PVm), defined as the point closest to the unsupported point (P2m) among the set (E0) of the points to bear that belong to the current layer (C,) and to the layers below the current layer.
    [0008]
    The method of any one of claims 5 to 7, including an additional step (116) of determining the plurality of points to be considered in the step (120) of testing a support condition, in the course of which the or each path (chi) is decomposed into elementary paths (sheik) extending between two successive angular points of said path, and, when the length of an elementary path is greater than a threshold length (1c), subdividing said path elementary in as many elementary paths, said plurality of points being constituted by the ends of each of the elementary paths.
    [0009]
    The method according to any one of claims 5 to 8, wherein the support condition tested on a point consists of calculating the fraction of the surface of a disk that covers the previous layer (CH1), said disk being centered. on the point considered and having a predefined radius, the considered point being unsupported when said fraction is less than a threshold fraction, for example 50%.
    [0010]
    10. A method according to any one of claims 5 to 9, wherein the set (E0) points to bear ensures that the filament is supported during the manufacture of the object by the implementation of a additive manufacturing process using a filament 3D printer.
    [0011]
    11. An information recording medium, characterized in that it comprises instructions for carrying out a method according to any one of claims 1 to 10, when the instructions are executed by an electronic computer.
    [0012]
    12. Support structure (10) for supporting an object (2) during its manufacture by implementing an additive manufacturing method, the support structure and the object being printed simultaneously, characterized in that it supports the object (2) in a plurality of points belonging to a set (E0) of the points to be supported resulting from the implementation of a method of determining a set of points to support according to any one of the claims 1 to 10.
    [0013]
    13. Structure according to claim 12, comprising at least one substantially vertical element between a point of contact (Pc) of a base plane and a point to be supported (Ps) on the surface of the object (2) belonging to the assembly (E0) of the points to be supported, said substantially vertical element being either a vertical pillar (14), connecting the point of contact and the point to be supported, or a vertical pillar (14) and a horizontal connector bridge (12C) connecting the upper end of said vertical pillar (14) to said point to be supported.
    [0014]
    14. Structure according to claim 12 or claim 13, composed of a plurality of bridges (12) horizontal and rectilinear, pillars (14) and vertical connectors (16) inclined, a lower end of a pillar resting on a bridge, on a base plane or on the surface of the object, and an upper end of a pillar carrying a connector, and a lower end of a connector resting at the upper end of a pillar and the end upper of a connector carrying a point to support the object or a point to support a bridge, each bridge being supported at least at each of its two end points, either by a pillar or by a point to support of the object.
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    同族专利:
    公开号 | 公开日
    US20180162058A1|2018-06-14|
    EP3152037B1|2021-04-14|
    FR3021902B1|2016-07-22|
    ES2879328T3|2021-11-22|
    EP3152037A1|2017-04-12|
    WO2015185845A1|2015-12-10|
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    2015-12-11| PLSC| Publication of the preliminary search report|Effective date: 20151211 |
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    2018-06-25| PLFP| Fee payment|Year of fee payment: 5 |
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    优先权:
    申请号 | 申请日 | 专利标题
    FR1455128A|FR3021902B1|2014-06-05|2014-06-05|METHOD FOR DETERMINING THE POINTS TO BE SUPPORTED FOR AN OBJECT MADE BY MEANS OF AN ADDITIVE MANUFACTURING PROCESS; INFORMATION RECORDING MEDIUM AND RELATED SUPPORT STRUCTURE|FR1455128A| FR3021902B1|2014-06-05|2014-06-05|METHOD FOR DETERMINING THE POINTS TO BE SUPPORTED FOR AN OBJECT MADE BY MEANS OF AN ADDITIVE MANUFACTURING PROCESS; INFORMATION RECORDING MEDIUM AND RELATED SUPPORT STRUCTURE|
    US15/316,440| US20180162058A1|2014-06-05|2015-06-02|Method for Determining the Points to be Supported for an Object Manufactured by Means of an Additive Manufacturing Method; Associated Information Recording Medium and Support Structure|
    ES15732832T| ES2879328T3|2014-06-05|2015-06-02|Procedure for determining the points to be supported for an object manufactured by means of an additive manufacturing process and information recording medium|
    PCT/FR2015/051447| WO2015185845A1|2014-06-05|2015-06-02|Method for determining the points to be supported for an object manufactured by means of an additive manufacturing method; associated information recording medium and support structure|
    EP15732832.9A| EP3152037B1|2014-06-05|2015-06-02|Method for determining the points to be supported for an object manufactured by means of an additive manufacturing method and information recording medium|
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