Systems and Methods for Preparing a Virtual Three-Dimensional (3D) Object for 3D Printing

Abstract

Computer-implemented systems and methods for preparing a virtual three-dimensional (3D) object for 3D printing are provided. A hollowed-out representation of an input model is generated. The input model defines a solid virtual 3D object, and the hollowed-out representation comprises a shell and an internal volume that is a void. The internal volume is meshed to generate a polygonal mesh representation of the internal volume. A lattice microstructure corresponding to the polygonal mesh representation is generated by (i) replacing each edge of the polygonal mesh representation with a solid part, and (ii) uniting the solid parts to form the lattice microstructure. A lightweight representation of the input model is generated, where the lightweight representation comprises the shell and the lattice microstructure.

What is claimed is: 
     
         1 . A computer-implemented method for printing a 3D object based on a virtual three dimensional (3D) object, the method comprising:
 receiving a model of a solid 3D object, the model including a shell and an internal volume that is a void;   meshing the internal volume to generate a polygonal mesh representation of the internal volume, wherein a density of edges in the polygonal mesh representation is controlled based on a stress analysis for the model;   generating a lattice microstructure corresponding to the polygonal mesh representation, wherein the lattice microstructure includes solid parts for the edges of the polygonal mesh; and   generating a lightweight representation for the solid 3D object, the lightweight representation comprising the shell and the lattice microstructure.   
     
     
         2 . The computer-implemented method of  claim 1 , further comprising:
 sending the lightweight representation to a 3D printer for creating the solid 3D object.   
     
     
         3 . The computer-implemented method of  claim 1 , wherein the model is based on a computer-aided design (CAD) model for a physical object. 
     
     
         4 . The computer-implemented method of  claim 1 , wherein the model comprises a closed triangle mesh. 
     
     
         5 . The computer-implemented method of  claim 4 , further comprising:
 offsetting the closed triangle mesh by a predetermined distance to generate an offset model; and   determining an intersection between the closed triangle mesh and the offset model, wherein the shell and the internal volume are represented based on the intersection.   
     
     
         6 . The computer-implemented method of  claim 1 , further comprising:
 receiving a selection of one or more faces or triangles of the model; and   generating a display for the 3D object based on the model, wherein the display does not include the selected one or more faces or triangles.   
     
     
         7 . The computer-implemented method of  claim 1 , wherein one of the solid parts of the lattice microstructure comprises a cylinder. 
     
     
         8 . The computer-implemented method of  claim 1 , wherein a density of edges in an area of the model is directly related to an amount of stress based on the stress analysis. 
     
     
         9 . The computer-implemented method of  claim 7 , wherein the generating of the lattice microstructure comprises:
 controlling one or more dimensions of the solid parts of the lattice microstructure based on the stress analysis for the model.   
     
     
         10 . The computer-implemented method of  claim 9 , wherein a radius of a cylinder or cone in an area of the model is directly related to an amount of stress based on the stress analysis. 
     
     
         11 . A system for preparing a virtual 3D object for 3D printing, the system comprising:
 a processing system; and   computer-readable memory in communication with the processing system encoded with instructions for commanding the processing system to execute steps comprising:
 receiving a model of a solid 3D object, the model including a shell and an internal volume that is a void; 
 meshing the internal volume to generate a polygonal mesh representation of the internal volume, wherein a density of edges in the polygonal mesh representation is controlled based on a stress analysis for the model; 
 generating a lattice microstructure corresponding to the polygonal mesh representation, wherein the lattice microstructure includes solid parts for the edges of the polygonal mesh; and 
 generating a lightweight representation for the solid 3D object, the lightweight representation comprising the shell and the lattice microstructure. 
   
     
     
         12 . The system of  claim 11 , further comprising:
 sending the lightweight representation to a 3D printer for creating the solid 3D object.   
     
     
         13 . The system of  claim 11 , wherein the model is based on a computer-aided design (CAD) model for a physical object. 
     
     
         14 . The system of  claim 11 , wherein the model comprises a closed triangle mesh. 
     
     
         15 . The system of  claim 14 , further comprising:
 offsetting the closed triangle mesh by a predetermined distance to generate an offset model; and   determining an intersection between the closed triangle mesh and the offset model, wherein the shell and the internal volume are represented based on the intersection.   
     
     
         16 . The system of  claim 11 , further comprising:
 receiving a selection of one or more faces or triangles of the model; and   generating a display for the 3D object based on the model, wherein the display does not include the selected one or more faces or triangles.   
     
     
         17 . The system of  claim 11 , wherein one of the solid parts of the lattice microstructure comprises a cylinder. 
     
     
         18 . The system of  claim 11 , wherein a density of edges in an area of the model is directly related to an amount of stress based on the stress analysis. 
     
     
         19 . The system of  claim 17 , wherein the generating of the lattice microstructure comprises:
 controlling one or more dimensions of the solid parts of the lattice microstructure based on the stress analysis for the model.   
     
     
         20 . A non-transitory computer-readable storage medium for preparing a virtual 3D object for 3D printing, the computer-readable storage medium comprising computer executable instructions which, when executed, cause a processing system to execute steps comprising:
 receiving a model of a solid 3D object, the model including a shell and an internal volume that is a void;   meshing the internal volume to generate a polygonal mesh representation of the internal volume, wherein a density of edges in the polygonal mesh representation is controlled based on a stress analysis for the model;   generating a lattice microstructure corresponding to the polygonal mesh representation, wherein the lattice microstructure includes solid parts for the edges of the polygonal mesh; and   generating a lightweight representation for the solid 3D object, the lightweight representation comprising the shell and the lattice microstructure.