Intuitive Creation System for Additive Manufacturing

Abstract

Described herein is an Intuitive Creation System for Additive Manufacturing (AM) Devices which automates the design and manufacturing process in order to minimize or eliminate the need to teach and train new users in the art of Additive Manufacturing (AM). This system and methodology allows anyone, with little to no technical know-how, to successfully operate an AM device to produce products that improve their quality of life, on demand, locally, and during events that cause disruption of traditional global manufacturing supply chains. Additionally, the described systems and methods also allow anyone to design and create products with little to no prior technical know-how. This is accomplished by integrating computational systems and processors into the physical device such that 3D model data can be interrupted and translated into actions by the AM device without the need for a highly trained operator or user.

What is claimed is: 
     
         1 . A method of producing a product from a three-dimensional (3D) model using an additive manufacturing (AM) device, the method comprising the steps of:
 turning on an additive manufacturing (AM) device and installing drivers for the AM device;   downloading and selecting settings for a slicing program associated with the AM device;   create a 3D model of the product to be produced by the AM device and scan the model to obtain model information about the model;   convert the model information to a .STL file type;   repair the .STL file;   orient, optimize, and slice the .STL file;   convert the .STL file into machine code;   level a printer bed of the AM device;   load material to be printed by the AM device into the AM device; and   activate the AM device to produce a product using the AM device.   
     
     
         2 . The method, according to  claim 1 , wherein the downloading and selecting settings for a slicing program associated with the AM device further comprises:
 pre-installing slicer software and settings on a computational device that is located on the AM device.   
     
     
         3 . The method, according to  claim 1 , wherein the create a 3D model of the product to be produced by the AM device and scan the model to obtain model information about the model further comprises:
 download and install a computer aided design (CAD) software;   create the 3D model of the product to be produced by the AM device; and   store the 3D model in a model repository.   
     
     
         4 . The method, according to  claim 1 , wherein the create a 3D model of the product to be produced by the AM device and scan the model to obtain model information about the model further comprises:
 create the 3D model of the product to be produced by the AM device;   take a picture of the 3D model; and   import the picture to a browser-based photogrammetry or 3D scanning based CAD program; and   store the 3D model in a model repository.   
     
     
         5 . The method, according to  claim 1 , wherein the repair of the .STL file further comprises:
 repair the .STL file to ensure that all selected .STL files are properly tessellated and have water-tight triangle meshes.   
     
     
         6 . The method, according to  claim 1 , wherein the orient, optimize, and slice the .STL file further comprises:
 analyzing each .STL file to determine a proper orientation of each .STL file; and   set the proper position of each .STL file within the build envelope.   
     
     
         7 . The method, according to  claim 1 , wherein the convert the .STL file into machine code further comprises:
 convert the .STL file into .gcode.   
     
     
         8 . The method, according to  claim 1 , wherein the level of a build platform bed of the AM device further comprises:
 determining an amount of unlevelness of the bed;   storing the amount of unlevelness of the bed; and   automatically adjusting a z-height of the bed throughout the production of the product such that a level surface of the printer bed is maintained.   
     
     
         9 . The method, according to  claim 4 , wherein the activate the AM device to produce a product using the AM device further comprises:
 obtaining 3D model information from the model repository or the 3D CAD program;   storing the 3D model information in a computation device of a printer;   obtaining information about the 3D model information from the 3D CAD program that is stored on the computational device of the printer; and   generating 3D models based on the 3D model information using the computational device systems and CAD program located on the printer.