U.S. patent application number 14/615389 was filed with the patent office on 2015-08-06 for system and methods for additively manufacturing highly customized structures.
This patent application is currently assigned to MetaMason, Inc.. The applicant listed for this patent is MetaMason, Inc.. Invention is credited to Leslie Oliver Karpas, Aaron M. Ryan.
Application Number | 20150217520 14/615389 |
Document ID | / |
Family ID | 53754099 |
Filed Date | 2015-08-06 |
United States Patent
Application |
20150217520 |
Kind Code |
A1 |
Karpas; Leslie Oliver ; et
al. |
August 6, 2015 |
System and Methods for Additively Manufacturing Highly Customized
Structures
Abstract
Systems and methods in accordance with embodiments of the
invention implement additive manufacturing processes to fabricate
highly customized products tailored to unique situations. In one
embodiment, a method of additively manufacturing a highly
customized product tailored to a particular individual includes:
obtaining relevant information pertaining to the particular
individual; developing a robust anthropomorphic model of the
particular individual; establishing a goal that the desired product
is intended to achieve; determining a design variable for the
product; simulating numerous instances of varying product designs;
determining at least one algorithm for assessing the efficacy of
each of the simulated product designs, the algorithm accounting for
the developed robust model; assessing the efficacy of each of the
simulated product designs using the determined at least one
algorithm; determining a product design suitable for fabrication
based on the assessment; and additively manufacturing the product
in accordance with the determined product design.
Inventors: |
Karpas; Leslie Oliver;
(Pasadena, CA) ; Ryan; Aaron M.; (Los Angeles,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MetaMason, Inc. |
Pasadena |
CA |
US |
|
|
Assignee: |
MetaMason, Inc.
|
Family ID: |
53754099 |
Appl. No.: |
14/615389 |
Filed: |
February 5, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61936263 |
Feb 5, 2014 |
|
|
|
Current U.S.
Class: |
700/98 |
Current CPC
Class: |
B29C 64/118 20170801;
B33Y 30/00 20141201; G06F 30/00 20200101; B29C 64/209 20170801;
B33Y 40/00 20141201 |
International
Class: |
B29C 67/00 20060101
B29C067/00; G06F 17/50 20060101 G06F017/50 |
Claims
1. A method of additively manufacturing a highly customized product
tailored to a particular individual comprising: obtaining
anthropomorphic information about the particular individual that
the product is meant for; developing an anthropomorphic model of
the particular individual that characterizes at least some aspect
of the particular individual's body and how it moves in space using
the obtained anthropomorphic information, using a computational
system; establishing at least one goal on the computational system
that the desired product is intended to achieve; determining on the
computational device at least one design variable for the product
based on the established goal; simulating numerous instances of
varying product designs on the computational device, the variations
being based on the established at least one design variable;
determining at least one algorithm for assessing the efficacy of
each of the simulated product designs on the computational device,
the algorithm accounting for the developed robust model; assessing
the efficacy of each of the simulated product designs using the
determined at least one algorithm on the computational device;
determining at least one product design suitable for fabrication
based on the assessment; and additively manufacturing the product
in accordance with the determined at least one product design.
2. The method of claim 1, wherein the computational device contains
machine learning algorithms that retain data obtained from
previously run methods of the additive manufacture of highly
customized products tailored to particular individuals, and uses
the data to inform at least one performed computation.
3. The method of claim 1, wherein the developed anthropomorphic
model characterizes how the particular individual's body deforms
when pressure is applied to it.
4. The method of claim 1, wherein establishing at least one goal on
the computational system is achieved by having a human input the
goal on the computational system.
5. The method of claim 1, wherein the determination of at least one
design variable is accomplished by a human inputting the determined
at least one design variable into the computational system.
6. The method of claim 1, wherein the determination of at least one
design variable is accomplished by the computational system.
7. The method of claim 1, wherein the at least one design variable
is the localized elastic characteristics of the desired
product.
8. The method of claim 1, wherein the at least one design variable
is the localized thickness characteristics of the desired
product.
9. The method of claim 1, wherein the at least one design variable
is the cell structure in any implemented Voronoi structures.
10. The method of claim 1, wherein thousands of instances of
varying product designs are simulated on the computational
system.
11. The method of claim 1, wherein millions of instances of varying
product designs are simulated on the computational system.
12. The method of claim 1, wherein the numerous instances of
varying product designs include redundant product designs.
13. The method of claim 1, wherein the determination of at least
one algorithm is accomplished by the computational system.
14. The method of claim 1, wherein the determination of at least
one algorithm is accomplished by a human inputting the determined
algorithm on the computational system.
15. The method of claim 1, wherein additively manufacturing the
product comprises using an active deposition technique.
16. The method of claim 1 wherein at least one established goal is
that the desired product implements a CPAP mask that is custom
fitted for the particular individual.
17. The method of claim 1, wherein at least one established goal is
a generative goal.
18. The method of claim 1, wherein at least one established goal is
that the desired product implements a shaper that is an article of
wear that tightly conforms to the particular individual's body and
is configured to motivate a predetermined figure.
19. The method of claim 1, wherein at least one established goal is
that the desired product provide footwear for that can enhance the
athletic performance of the particular individual.
20. The method of claim 1, wherein at least one established goal is
that the desired product provide comfortable footwear for the
particular individual.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The current application claims priority to U.S. Provisional
Patent Application No. 61/936,263, filed Feb. 5, 2014, the
disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to techniques for
additively manufacturing highly customized structures.
BACKGROUND
[0003] `Additive manufacturing,` or `3D Printing,` is a term that
typically describes a manufacturing process whereby a 3D model of
an object to be fabricated is provided to an apparatus (e.g. a 3D
printer), which then autonomously fabricates the object by
gradually depositing, or otherwise forming, the constituent
material in the shape of the object to be fabricated. For example,
in many instances, successive layers of material that represent
cross-sections of the object are deposited or otherwise formed;
generally, the deposited layers of material fuse (or otherwise
solidify) to form the final object. Because of their relative
versatility, additive manufacturing techniques have generated much
interest.
SUMMARY OF THE INVENTION
[0004] Systems and methods in accordance with embodiments of the
invention implement additive manufacturing processes to fabricate
highly customized products tailored to unique situations. In one
embodiment, a method of additively manufacturing a highly
customized product tailored to a particular individual includes:
obtaining relevant information pertaining to the particular
individual that the desired product is meant for; developing a
robust anthropomorphic model of the particular individual using the
obtained relevant information; establishing a goal that the desired
product is intended to achieve; determining at least one design
variable for the product based on the established goal; simulating
numerous instances of varying product designs, the variation being
based on the determined at least one design variable; determining
at least one algorithm for assessing the efficacy of each of the
simulated product designs, the algorithm accounting for the
developed robust model; assessing the efficacy of each of the
simulated product designs using the determined at least one
algorithm; determining at least one product design suitable for
fabrication based on the assessment; and additively manufacturing
the product in accordance with the determined at least one product
design.
[0005] In another embodiment, a method of additively manufacturing
a highly customized product tailored to a particular individual
includes: obtaining anthropomorphic information about the
particular individual that the product is meant for; developing an
anthropomorphic model of the particular individual that
characterizes at least some aspect of the particular individual's
body and how it moves in space using the obtained anthropomorphic
information, using a computational system; establishing at least
one goal on the computational system that the desired product is
intended to achieve; determining on the computational device at
least one design variable for the product based on the established
goal; simulating numerous instances of varying product designs on
the computational device, the variations being based on the
established at least one design variable; determining at least one
algorithm for assessing the efficacy of each of the simulated
product designs on the computational device, the algorithm
accounting for the developed robust model; assessing the efficacy
of each of the simulated product designs using the determined at
least one algorithm on the computational device; determining at
least one product design suitable for fabrication based on the
assessment; and additively manufacturing the product in accordance
with the determined at least one product design.
[0006] In yet another embodiment, the computational device contains
machine learning algorithms that retain data obtained from
previously run methods of the additive manufacture of highly
customized products tailored to particular individuals, and uses
the data to inform at least one performed computation.
[0007] In still another embodiment, the developed anthropomorphic
model characterizes how the particular individual's body deforms
when pressure is applied to it.
[0008] In yet still another embodiment, establishing at least one
goal on the computational system is achieved by having a human
input the goal on the computational system.
[0009] In a further embodiment, the determination of at least one
design variable is accomplished by a human inputting the determined
at least one design variable into the computational system.
[0010] In a still further embodiment, the determination of at least
one design variable is accomplished by the computational
system.
[0011] In a yet further embodiment, the at least one design
variable is the localized elastic characteristics of the desired
product.
[0012] In a still yet further embodiment, the at least one design
variable is the localized thickness characteristics of the desired
product.
[0013] In another embodiment, the at least one design variable is
the cell structure in any implemented Voronoi structures.
[0014] In yet another embodiment, thousands of instances of varying
product designs are simulated on the computational system.
[0015] In still another embodiment, millions of instances of
varying product designs are simulated on the computational
system.
[0016] In still yet another embodiment, the numerous instances of
varying product designs include redundant product designs.
[0017] In a further embodiment, the determination of at least one
algorithm is accomplished by the computational system.
[0018] In a yet further embodiment, the determination of at least
one algorithm is accomplished by a human inputting the determined
algorithm on the computational system.
[0019] In a still further embodiment, additively manufacturing the
product includes using an active deposition technique.
[0020] In a still yet further embodiment, at least one established
goal is that the desired product implements a CPAP mask that is
custom fitted for the particular individual.
[0021] In another embodiment, at least one established goal is a
generative goal.
[0022] In still another embodiment, at least one established goal
is that the desired product implements a shaper that is an article
of wear that tightly conforms to the particular individual's body
and is configured to motivate a predetermined figure.
[0023] In yet another embodiment, at least one established goal is
that the desired product provide footwear for that can enhance the
athletic performance of the particular individual.
[0024] In still yet another embodiment, at least one established
goal is that the desired product provide comfortable footwear for
the particular individual.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 illustrates a method of manufacturing a highly
customized product tailored to a particular individual in
accordance with certain embodiments of the invention.
[0026] FIGS. 2A-2D illustrate the mechanics of a 6-axis 3D printer
relative to a conventional 3D printer.
[0027] FIGS. 3A-3D illustrate varying lattice structures that can
be implemented within additively manufactured products to customize
the localized elastic characteristics in accordance with certain
embodiments of the invention.
[0028] FIG. 4 illustrates a `pressure map` obtained for a
particular individual's foot that can be used in the computation of
the design characteristics for a shoe customized for the particular
individual in accordance with an embodiment of the invention.
[0029] FIGS. 5A-5C illustrate Voronoi diagrams that characterize
desired design structures for a shoe customized for a particular
individual that can be computed using a provided corresponding
pressure map accordance with an embodiment of the invention.
[0030] FIGS. 6A-6B illustrate a shoe additively manufactured in
accordance with computed desired design characteristics in
accordance with an embodiment of the invention.
[0031] FIGS. 7A-7B illustrate the reshaping of the contours of a
particular individual's body using a highly customized muscle shirt
that can be additively manufactured in accordance with an
embodiment of the invention.
[0032] FIGS. 8A-8B illustrate a highly customized muscle shirt
tailored to reshape the contours of a particular individual's body
additively manufactured in accordance with an embodiment of the
invention.
[0033] FIGS. 9A-9B illustrate the additive manufacture of a highly
customized bra in accordance with an embodiment of the
invention.
[0034] FIGS. 10A-10F illustrate thermal imaging views that convey
the subcutaneous facial structure information of a particular
individual that can be used to inform the design of a highly
customized continuous positive airway pressure ("CPAP") mask in
accordance with an embodiment of the invention.
[0035] FIGS. 11A-11E illustrate a highly customized CPAP mask
tailored for a particular individual additively manufactured in
accordance with an embodiment of the invention.
[0036] FIG. 12 illustrates a method for additively manufacturing a
highly customized product in accordance with an embodiment of the
invention.
DETAILED DESCRIPTION
[0037] Turning now to the drawings, systems and methods for
implementing additive manufacturing processes that fabricate highly
customized products that are tailored for unique situations are
illustrated. In many embodiments, a method of manufacturing a
product tailored for a particular individual includes: obtaining
relevant information regarding the particular individual that the
desired product is meant for; developing a robust anthropomorphic
model of the particular individual using the obtained relevant
information; establishing a goal that the desired product is
intended to achieve; determining at least one design variable for
the product based on the established goal; numerous instances of
varying product designs, the variation being based on the
determined at least one design variable; determining at least one
algorithm for assessing the efficacy of each of the simulated
product designs, the algorithm accounting for the developed robust
model; assessing the efficacy of each of the simulated product
designs using the determined at least one algorithm; determining at
least one product design suitable for fabrication based on the
assessment; and additively manufacturing the product in accordance
with the determined at least one product design. In numerous
embodiments, the product that is manufactured is an article of wear
for a particular individual. In a number of embodiments, the at
least one design variable is the localized elastic characteristics
within the product. In various embodiments, the established goal is
based on treating sleep apnea for a particular individual, e.g. via
providing continuous positive airway pressure (for instance, as
conventional CPAP masks do). In many embodiments, where the product
to be manufactured is a CPAP mask, the obtained relevant
information includes the geometry of a target user's face. In many
embodiments, where the product to be manufactured is a CPAP mask,
the established goal is based on treating sleep apnea using a CPAP
mask that is designed to reduce potential discomfort experienced by
the user when the CPAP mask is worn. In further embodiments, the
established goal is based on facilitating laminar air flow through
CPAP mask.
[0038] Since its inception, additive manufacturing, or `3D
Printing`, has generated much interest from manufacturing
communities because of the seemingly unlimited potential that these
fabrication techniques can offer. For example, these techniques
have been demonstrated to produce any of a variety of distinct and
intricate geometries, with the only input being the final shape of
the object to be formed. In many instances, a 3D rendering of an
object is provided electronically to a `3D Printer`, which then
fabricates the object. Many times, a 3D Printer is provided with a
CAD File, a 3D Model, or instructions (e.g. via G-code), and the 3D
Printer thereby fabricates the object. Importantly, as can be
inferred, these processing techniques can be used to avoid heritage
manufacturing techniques that can be far more resource intensive
and inefficient. The relative simplicity and versatility of these
techniques can pragmatically be used in any of a variety of
scenarios including for example to allow for rapid prototyping
and/or to fabricate components that are highly customized for
particular consumers. For example, shoes that are specifically
adapted to fit a particular individual can be additively
manufactured. Indeed, U.S. Provisional Patent Application No.
61/861,376 discloses the manufacture of customized medical devices
and apparel using additive manufacturing techniques; U.S.
Provisional Patent Application No. 61/861,376 and its progeny are
hereby incorporated by reference in its entirety, especially as
they pertain to the additive manufacture of customized articles. It
should also be mentioned that the cost of 3D printers has recently
noticeably decreased, thereby making additive manufacturing
processes an even more viable fabrication methodology.
[0039] Given the demonstrated efficacy and versatility of additive
manufacturing processes, their potential continues to be explored.
For example, while the operation of many current generation
additive manufacturing apparatuses is premised on the uniform
deposition of a material in the shape of the desired object such
that the material properties of the corresponding printed object
are largely homogenous throughout its structure, in many instances
it may be desirable to additively manufacture multi-material
objects. Accordingly, additive manufacturing apparatuses and
techniques have recently been developed that can selectively
deposit any of a plurality of different materials during the
buildup of a desired object such that the printed object can be
made up of a plurality of different materials. For example,
Stratasys is a 3D Printing Company that develops 3D printers that
can deposit any of a plurality of materials during the buildup of a
single printed object, i.e. the printed object can be printed to
include a plurality of distinct materials. For instance, the Objet
Connex line of printers developed by Stratasys is adept at such
`multi-material printing.` Incidentally, Stratasys also boasts of
its PolyJet Technology which allows 3D printing resolutions as fine
as 0.0006'' per layer of deposited material to be achieved. PolyJet
technology essentially involves depositing a plurality of drops of
liquid photopolymer onto a build tray, and instantly uniformly
curing the deposited drops with UV light.
[0040] Moreover, U.S. patent application Ser. No. 14/321,046,
applied for by MetaMason, Inc., discloses additive manufacturing
processes whereby the constituent material of an object to be
fabricated is actively manipulated prior to, or during, the
deposition process, such that different portions of the deposited
constituent material can be made to possess different material
properties; these deposition techniques can be referred to as
`active deposition.` U.S. patent application Ser. No. 14/321,046 is
hereby incorporated by reference in its entirety, especially as it
pertains to additively manufacturing objects that possess
non-homogenous materials properties.
[0041] Nonetheless, even with these laudable achievements, the
state of the art can further benefit from efficient and efficacious
additive manufacturing techniques that fabricate highly-customized
products tailored to particular individuals, featuring particularly
implemented design characteristics, e.g. customized elastic
characteristics. Thus, the instant application discloses
efficacious and efficient additive manufacturing techniques for
fabricating such highly customized products tailored to particular
individuals, which utilize computationally derived design
characteristics. For example, in one disclosed embodiment, a
process for fabricating a highly customized CPAP mask tailored to a
particular individual is implemented. Tailored CPAP masks can offer
a host of advantages relative to conventional off the shelf CPAP
masks. For instance, they can be worn with relatively less
discomfort compared to conventional CPAP masks, which in turn can
promote more consistent usage by the individual, and promote
his/her wellbeing. These processes are now discussed in greater
detail below.
Methods for Additively Manufacturing Highly-Customized Products for
Unique Situations
[0042] In numerous embodiments of the invention, additive
manufacturing processes are implemented that fabricate
highly-customized products tailored to unique situations. In many
embodiments, the additive manufacturing processes rely on rigorous
computation to derive a set of desirable design characteristics.
For example, FIG. 1 illustrates a generalized process for
fabricating a highly-customized product for a unique situation that
relies on rigorous computation in accordance with certain
embodiments of the invention. In particular, the method 100
includes obtaining 102 relevant information regarding the
particular individual that the product is meant for. As can be
appreciated, the information deemed relevant can be
context-dependent; in general, any piece of information can be
found to be relevant and obtained 102 in accordance with many
embodiments of the invention. For example, where the desired
product is an article of wear customized for a particular
individual, the geometry of the specific individual's respective
body part(s) that the article of wear is meant to be worn over can
be obtained 102. Notably, any of a variety of techniques can be
used to obtain the relevant information. For example, in many
embodiments, a 3D scanner is used to obtain 102 the geometry of the
body part(s) that a desired article of wear is meant for. The
obtaining of relevant information is described in greater detail in
subsequent sections of the application.
[0043] The method 100 further includes developing 104 a robust
anthropomorphic model of the particular individual using the
obtained 102 information. For example, where the desired product is
a shaper (i.e. an article of wear that typically tightly conforms
to an individual's body and is intended to motivate a particular
figure) designed for a particular individual, the developed model
can be an anthropomorphic model that characterizes the particular
individual's body. Moreover, the anthropomorphic model can be
robust insofar as it accounts for the way the particular
individual's body changes as it is reoriented in space (e.g. it
accurately reflects the shaping of the particular individual's body
as he/she is standing, sitting, or walking). While the instant
method 100 is described with respect to fabricating products
tailored to particular individual, it should be emphasized that the
method can be generalized and applied to any of a variety of unique
situations. For example, relevant information about a unique
situation that a product is meant for can be obtained, and a robust
model of the unique situation can be developed based on the
obtained relevant information in accordance with embodiments of the
invention. Generally, embodiments of the invention are not limited
to designing and fabricating products for particular individuals;
embodiments of the invention include designing and fabricating
products for unique situations. The development of a robust model
is described in greater detail in subsequent sections of the
application.
[0044] The method 100 further includes establishing 106 a goal that
the desired product is intended to achieve; any appropriate goal
can be established in accordance with many embodiments of the
invention. For example, in many embodiments, where the desired
product is a shaper customized for a particular individual, the
goal that is established 106 is the goal of having the shaper be
capable of contorting the individual's body into a predefined
figure in any of a variety of stances--e.g. the shaper should be
capable of motivating a particular figure in the target individual
regardless of whether the individual is standing or sitting. The
establishing of a goal is described in greater detail in subsequent
sections of the application.
[0045] The method 100 further includes determining 108 at least one
product design variable based on the established goal. For example,
where the desired product is a shaper, the at least one product
design variable can be the localized elastic characteristics of the
shaper. Additionally, the determination 108 can be carried out in
any suitable way. For example, the determination 108 of the at
least one product design variable can be conducted computationally,
or it can be established by a human. In general, any suitable way
of determining at least one product design variable based on the
established goal can be implemented in accordance with embodiments
of the invention. The determining of at least one product design
variable based on the established goal is described in greater
detail in subsequent sections of the application.
[0046] The method 100 further includes simulating 110 numerous
instances of varying product designs, the variations being based on
the determined at least one design variable. For example, where a
shaper is the product to be manufactured, numerous instances of the
shaper can be computationally simulated, the simulated numerous
instances including shapers having various elastic characteristics.
Moreover, in many embodiments, a vast number of such instances are
simulated. For example, in some embodiments thousands of instances
are simulated; in a number of embodiments, hundreds of thousands of
instances are simulated; in many embodiments, millions of instances
are simulated. Accordingly, in many embodiments, the simulations
can be computationally intensive. In general, any number of
instances can be simulated in accordance with embodiments of the
invention. The simulation of numerous instances of varying product
designs is described in greater detail in subsequent sections of
the application.
[0047] The method 100 further includes determining 112 at least one
algorithm for assessing the efficacy of the simulated product
designs, the algorithm accounting for the developed robust model.
Thus, for instance, where the desired product is a shaper that
contorts a particular individual's body into a certain figure, the
determined algorithm can measure how well each of the simulated
designs, as applied to the robust model, contorts body into the
desired shape. The determination 112 of the algorithm can be
achieved in any suitable way in accordance with certain embodiments
of the invention. For example, in many embodiments, the
determination is achieved computationally. In several embodiments,
the determination 112 is made by a human. The determination of at
least one algorithm for assessing the efficacy of each of the
simulated product designs is described in greater detail in
subsequent sections of the application.
[0048] The method 100 further includes assessing 114 the efficacy
of each of the simulated product designs using the determined at
least one algorithm. In many embodiments, algorithm is applied to
each of the simulated product designs as applied to the developed
robust model, and the efficacy of each of the simulated product
designs is thereby assessed. For example, where the desired product
is a shaper, the algorithm can be applied to assess the efficacy of
each of the simulated shapers (e.g. in view of the established
goal) as applied to the robust model. The assessing of the efficacy
of each of the simulated product designs using the determined at
least one algorithm is described in greater detail in subsequent
sections of the application.
[0049] The method 100 further includes determining 116 at least one
product design suitable for fabrication based on the assessment.
Thus, in some embodiments, a single product design is
computationally determined as the algorithm deemed this product
design more efficacious relative to the other product designs. In
some embodiments, several product designs are determined, and
offered to a human for final determination as to which of the
several designs are to be fabricated. The determination of at least
one product design suitable for fabrication is described in greater
detail in subsequent sections of the application.
[0050] The method 100 further includes additively manufacturing 118
the desired product in accordance with the determined at least one
product design. Any of a variety of additive manufacturing
techniques can be implemented. For example, in some embodiments,
For example, the investment molding techniques described in U.S.
patent application Ser. No. 14/173,549, applied for by MetaMason,
Inc., and PCT Patent Application No. PCT/US2014/049481, also
applied for by Metamason, Inc., can be implemented in accordance
with embodiments of the invention. The disclosures of U.S. patent
application Ser. No. 14/173,549 and PCT Patent Application No.
PCT/US2014/049481 are hereby incorporated by reference in their
entirety, especially as they regard investment molding techniques.
Additionally, as can be appreciated, in many embodiments, it is
desirable that the highly customized products have varying
materials properties throughout their structure. Thus, in many
embodiments, the implemented additive manufacture techniques
utilize active deposition techniques as disclosed in U.S. patent
application Ser. No. 14/321,046, incorporated by reference above,
which are well-suited to implementing structures having varying
materials properties. But of course, it should be clear that any of
a variety of deposition techniques can be implemented. The additive
manufacture of the desired product in accordance with the at least
one product design is described in greater detail in subsequent
sections of the application.
[0051] As can be appreciated, the above-described method is general
and can be applied in any of a variety of contexts, and can be used
to fabricate any of a variety of products in accordance with
embodiments of the invention. While certain examples have been
mentioned, the described examples should not be construed as
limiting the scope of the described methods. Note that the
described methods can be achieved in any suitable way. In many
embodiments, the many of the described aspects of the method are
substantially performed on a device capable of computation
including, but not limited to: a personal computer; a
supercomputer; a tablet computer; and a cell phone. In general, any
suitable device capable of such computations can be implemented. In
many embodiments, many of the described aspects are substantially
performed in a cloud server context. In numerous embodiments, such
computational systems are well configured to handle `big data`, and
implement associated algorithms, e.g. HADOOP and MAPREDUCE.
Moreover, where the described processes are implemented on a
computational system, the data passed back and forth can be
encrypted. For example, where the product to be fabricated is a
therapeutic device, and compliance with HIPAA privacy laws is
desired, encryption techniques that satisfy the HIPAA privacy laws
can be implemented.
[0052] Furthermore, it should be understood that the described
aspects of the described methods can occur in any of a variety of
sequences in accordance with embodiments of the invention. The
order of the description is not meant to necessarily imply a
particular order of operation. For example, in many embodiments,
establishing a goal that the desired product is intended to achieve
occurs prior to obtaining relevant information regarding the unique
situation that the desired product is meant for.
[0053] Furthermore, while certain methods have been described, it
should be understood that any of a variety of methods for
fabricating highly customized products tailored to unique
situations can be implemented. For example, any of a variety of
computational methods can be implemented to derive a design for a
desired product that can subsequently be additively manufactured.
Moreover, in many embodiments, the described methods are modified
so that they are used only to determine a desirable set of design
characteristics for a desired product for a unique situation; they
are not used to additively manufacture the product in accordance
with the derived design characteristics. Thus, in many embodiments,
the aspect of additively manufacturing the desired product is
omitted. In several embodiments, the described methods further
implement machine-learning algorithms that retain data from
previously implemented methods and utilize this data to inform the
operation of further methods. In general, as can be appreciated,
the above-described methods can be implemented/modified in any of a
variety of ways in accordance with embodiments of the invention.
Thus, the description should not be construed as limiting. The
aspects of the above described methods are now discussed in greater
detail below.
Obtaining Relevant Information Regarding a Unique Situation that a
Desired Product is Meant for
[0054] In many embodiments, relevant information regarding the
unique situation that a desired product is to be additively
manufactured for is obtained. As alluded to above, any of a variety
of pieces of information can be deemed relevant and obtained; the
particular pieces of information that are to be obtained can be
largely context dependent. For example, in many embodiments,
relevant information concerning the particular individual (e.g.
his/her anatomical features) that the product is meant for is
obtained, as many embodiments are implemented to fabricate products
designed to fit particular individuals. For instance, in many
embodiments, an additive manufacturing process for fabricating a
highly-customized CPAP mask tailored for a particular individual is
implemented. Accordingly, in many embodiments, the facial
structure, including the particular nostril structure, of the user
is obtained. This information can allow the CPAP mask to be
additively manufactured so that it closely conforms to the
particular user's facial contours, and thereby allows for
comfortable wear. Moreover, with information concerning the
individual's nostril structure, the CPAP mask can be additively
manufactured such that it tightly conforms to the individual's
nostrils, and thereby creates a tight seal, which can reduce
undesirable leakage and allow for more effective mask
operation.
[0055] Furthermore, in a number of embodiments, information
concerning the subcutaneous structure (e.g. the physiological
makeup of the facial structure under the skin) of the user's face
is obtained. This information can be used to further inform the
design of the CPAP mask. For example, information concerning the
subcutaneous structure can be used to determine whether, and where,
to make certain portions of the mask more or less elastic. For
instance, wherever bone structure is detected, the CPAP mask can be
designed such that it is more elastic at those regions to
accommodate the rigid bone structure. In many embodiments,
information regarding the subcutaneous structure can be used to
allow the CPAP mask to be designed such that it includes moduli of
elasticity that correspond with those of the associated localized
regions of the face. This can allow the CPAP mask to retain its
orientation when worn (e.g. if the individual is moving while
sleeping). While several examples of relevant information are given
for the additive manufacture of a CPAP mask, it should be clear
that any of a variety of pieces of information can be deemed
relevant and obtained in accordance with embodiments of the
invention. For example, in many embodiments, information related to
the health of the individual can be obtained, including but not
limited to: the age of the individual, the individual's health
history, information related to individual's lung capacity and/or
typical breathing pattern; information concerning pulse oximetry,
blood pressure, blood type, glucose levels, heart rate, EKG, MRI,
PET, CT, IMS, genomics/binomics, and/or dermatological information
can be obtained.
[0056] Additionally, as mentioned previously, it should be clear
that the methodologies discussed in this application can be used to
fabricate any of a variety of objects, and not just CPAP masks.
Accordingly, it can be appreciated that the relevant information
will depend on the particular product that is being additively
manufactured, and its intended use. Thus, for instance, in many
embodiments of the invention, the above-described methodologies are
used to fabricate highly customized footwear tailored to a
particular individual. Accordingly, the relevant information that
is obtained can include (but is not limited to) the individual's
foot structure, his/her typical walking/running/movement pattern,
as well as the individual's principal intended use of the footwear
(e.g. active wear or casual wear). As can be appreciated, each of
these pieces of information can be informative in determining
desirable design characteristics. In effect, it is seen that the
above-described methodologies are general in nature and can be used
to additively manufacture any of a variety of highly customized
products for unique situations; accordingly, any of a variety of
pieces of information can be deemed relevant and obtained so as to
inform the design characteristics of the desired product.
[0057] The identified relevant information can also be obtained
using any of a variety of techniques in accordance with embodiments
of the invention. For example, in many embodiments a highly
customized article of wear tailored for a unique individual is
additively manufactured, and the relevant information that is
obtained includes the geometry of the individual's body part(s)
that the article of wear is to fit over. Accordingly, a 3D scanner
can be used in accordance with embodiments of the invention to
obtain the geometry information. Similarly, where a CPAP mask is to
be additively manufactured, a 3D scanner can be used to obtain the
geometry of the target user's facial structure. Of course, it
should be understood that any suitable 3D scanner can be
implemented. For example, in many embodiments, a FUEL 3D or
Structure.IO scanner is used. Although, it should be reiterated
that any suitable 3D scanner can be used, and more generally, any
suitable way of obtaining the relevant information can be
implemented. 3D scanning techniques are particularly effective
insofar as the obtained data can be immediately provided to a
device capable of computation (e.g. a computer) for subsequent
computation.
[0058] Additionally, as discussed above, in many embodiments,
subcutaneous information is considered relevant and is obtained.
Similar to before, any suitable way for obtaining the subcutaneous
structure information can be implemented. For instance, in many
embodiments, thermal imaging techniques are used to obtain
information concerning subcutaneous structure. Additionally, where
stride and gait information are relevant and obtained, e.g. for the
additive manufacture of highly customized footwear, this
information can be obtained by video recording the particular
individual's movement pattern. In several embodiments, a 3D video
recording of the particular individual's movement pattern is
obtained. Similarly, the pressure experienced by the individual's
feet while standing can be relevant and obtained. For instance, the
individual can be instructed to stand on a pressure-sensitive
platform that measures localized pressure; all of this information
can be used to inform the design of tailored additively
manufactured footwear.
[0059] In general, as can be appreciated from the above discussion,
any of a variety of pieces of information can be deemed to be
relevant, and can be obtained in any of a variety of appropriate
ways in accordance with embodiments of the invention. For instance,
in some embodiments acoustic data is considered to be relevant, and
obtained via an stereo recording. This obtained information can
then be used to inform the final design characteristics of the
desired product. In many embodiments, this obtained relevant
information is provided as inputs for computation/simulation, and
computations are performed so as to derive desirable design
characteristics for the product to be manufactured. The development
of a robust model of the unique situation using the obtained
relevant information is now discussed below.
Developing a Robust Model of the Unique Situation Using the
Obtained Relevant Information
[0060] In many embodiments, a robust model of the unique situation
using the obtained relevant information is developed. In many
embodiments, the methodologies are used to fabricate products
tailored to particular individuals; accordingly, in many
embodiments, robust anthropomorphic models of the particular
individuals are developed. The development can occur in any of a
number of ways. In many embodiments a device capable of computation
is used to develop the robust model. Thus, for example, where the
desired product is a shaper for a particular individual, the robust
model that can be developed is an anthropomorphic model of the
particular individual. In many embodiments, the anthropomorphic
model is sufficiently intricate that it accounts for the
deformability of the individual, e.g. how which aspects of the
individual are soft and deformable (e.g. flesh) and which aspects
are hard and rigid (e.g. bony structure). In several embodiments,
the anthropomorphic model accounts for the kinematic abilities of
the particular individual (e.g. how the individual moves in space).
The anthropomorphic model can be developed by aggregating the
obtained relevant information--e.g. in the form of computer data,
and interpreting it appropriately. For example, obtained relevant
data including the geometry of the individual (e.g. obtained via a
3D scan), the subcutaneous structure of the individual (e.g.
obtained via thermal imaging), and kinematic data (e.g. obtained
via 3D recording of the individual in motion), can be
computationally aggregated and used to develop the robust
anthropomorphic model. As can be appreciated, the associated
computations can be computationally intensive, and may be performed
on an appropriately robust computationally capable system. For
example, in many embodiments, the computations are performed on a
supercomputer. In several embodiments, the computations are
achieved in a cloud based system. As can be appreciated, the
computationally capable systems can be configured to handle "big
data"--e.g. they can be configured to implement HADOOP and/or
MAPREDUCE algorithms where necessary. It should of course be
appreciated that the computations can occur on any suitable system
in accordance with embodiments of the invention, and are not
limited to the described systems.
[0061] In many embodiments, the complexity of the robust model
correspond to the desired fidelity in the determination of the
final design characteristics for the desired part. Thus, where
greater fidelity in the determined design characteristics is
desired, the robust model is made to be more complex, and vice
versa.
[0062] Note that while the development of an anthropomorphic model
corresponding to a particular individual has been discussed, it
should be clear that the development of a robust model can adopt
any of a variety of forms in accordance with embodiments of the
invention. For example, in some instances, the above-described
methods are used to fabricate a CPAP mask, and the development of a
robust model in this instance regards modeling only the facial
structure. In general, any suitable robust model that can
facilitate the derivation of desirable design characteristics can
be developed in accordance with embodiments of the invention.
Moreover, while the development of robust models regarding humans
is discussed, the above-described techniques are broad and can be
applied in any of a variety of situations. For instance, in some
embodiments, the methods are applied to products for animals, and
robust models of the animals are developed. More generally, the
methods can be applied to any situation, not just those concerning
humans/animals. Any of a variety of unique situations can be
modeled in accordance with embodiments of the invention.
[0063] In many embodiments, at least one goal for the product is
established, and this aspect is now discussed below.
Establishing a Goal that the Desired Product is Intended to
Achieve
[0064] In many embodiments, a goal that the desired product is
intended to achieve is established. In a number of embodiments,
measurable criterion can be determined to assess to what extent the
goal is being achieved. Thus for instance, where a CPAP mask is to
be fabricated, the established goal can be to `implement a CPAP
mask that can deliver sealed airflow through the nasal passages.`
Note that the generality of the goal statement can be varied based
on the tolerability of the design variation. Thus for instance, in
some embodiments, the established goal is more generally phrased as
`expose a particular individual's nasal passage to a positive air
pressure so as to maintain the clearance of the nasal passages.` In
general, the level of generality of the goal statement can be
scaled in accordance with the tolerance of the flexibility of the
design constraints: where the design is allowed to be more
flexible, the established goal can be phrased more generally, and
vice versa. For example, in some embodiments, the established goal
is most generally phrased as `resolve a particular individual's
sleep apnea.` Such a broad goal statement can for example allow a
computer to computationally derive an adequate solution. As can be
appreciated, such a method would be best implemented on a
sufficiently powerful computing system.
[0065] In general, the establishment of a goal can be accomplished
by specifying what the desired product is, and can also be
accomplished by specifying what the desired outcome is. Where the
establishment of a goal is accomplished by specifying what the
desired product is, the goal establishment can be thought of as
`deterministic` (e.g. it is `pre-determined` what the final product
is intended to be) Where the establishment of a goal is
accomplished by specifying what the desired outcome is, the goal
establishment can be thought of as `generative` (e.g. the final
product that will accomplish the goal will be `generated.`) The
establishment of `generative` goal statements can be somewhat
thought of as allowing a solution to evolve. In other words, there
is no bias toward a particular design; rather, a device capable of
computation (e.g. a super-computer) can derive a suitable solution
by simulating the testing of a vast number of designs, and
converging on those that are most efficacious. This process can be
thought of as being bio-mimetic.' In a number of embodiments, both
deterministic goal statements are established and generative goal
statements are established. In general, any of a variety of goal
statements can be established.
[0066] It should be appreciated that the goal statement is
substantially context-dependent, and can be manifested in any of a
variety of ways. For example, where a shaper is to be implemented,
the establishment of the goal can pertain to contorting a
particular individual to a specified form. Where footwear is to be
implemented, the establishment of the goal can pertain to, for
example improving athletic performance for a particular individual
and/or providing comfort for walking for a particular user.
Notably, in many instances, a plurality of goals are established,
and the derived design characteristics are derived so as to
accommodate each of them to the extent possible. Any number of
goals can be established in accordance with embodiments of the
invention.
[0067] Based on the established goal statement, suitable design
criterion that can be varied can be determined, and this aspect is
now discussed in greater detail below.
Determination of Product Design Variables
[0068] In many embodiments, based on the established goal, suitable
product design variables are determined. Suitable design variables
can be determined in any appropriate way in accordance with
embodiments of the invention. For example, they can be
computationally determined. In numerous embodiments, the suitable
design variables are manually determined (e.g. determined by a
human). This aspect can be thought of as parameterization. For
example, in many embodiments, the design variables include at least
one of: multi-material cell lattice sizing; material property
control; printing/fabrication process & materials selection;
tool pathing, controlling microstructure; cross-sectional
structure; surface features, e.g. ribs, contours, tread. In other
words, cell structures (e.g. Voronoi structures) can be implemented
to form the material, and the sizing and composition of the cell
structures can be varied. Additionally, the material properties can
be directly varied (e.g. via active deposition techniques). The
additive manufacturing process and material selection can be
varied. The tool pathing, which can impact the design
characteristics of the structure, can be varied. The cross-section
of the deposited constituent material can be varied. And the
surface features can be varied. Of course, as can be appreciated,
any of a variety of suitable design variables can be established.
For example, where a shaper is to be fabricated, the design
variables can include the localized elastic characteristics. Where
a CPAP mask is to be fabricated, the design characteristics can
include the localized elastic characteristics as well as the
structure of the inner walls of any passages related to the
airflow. Where a shoe is to be fabricated, the product design
variables can include the elastic characteristics of the sole of
the shoe, as implemented via a Voronoi structure. As can be
appreciated, any of a variety of suitable product design variables
can be established.
[0069] Based on the determined product design variable(s), numerous
instances embodying various design configurations of the product
can be generated, and this aspect is now discussed in greater
detail below.
Simulating Varying Product Designs
[0070] In many embodiments, numerous instances embodying varying
product designs are simulated. In many embodiments, the number of
simulations is voluminous, and the simulations are meant to
encompass a substantial portion of the universe of possible
designs. The simulated product designs can vary based on the
determined product design variables. In many embodiments, each
simulation is performed on a separate `server blade`, and is
assigned a unique identifier. In numerous embodiments, redundant
simulations are also established, e.g. consistent with notions
underlying the APACHE HADOOP framework. For example, in many
embodiments at least three simulations of the identical simulated
product are instantiated. In general, many embodiments are
compatible with conventional understanding of "Big Data"
frameworks. In many embodiments, a naming node is also created, and
is replicated to avoid losing data.
[0071] In a number of embodiments separate sets of simulations are
established for each of the generative goal statements and the
deterministic goal statements. In this way, the efficacy of
generative solutions can be compared with the efficacy of
pre-determined form-factors. As one example, in embodiments where a
solution for sleep apnea are to be additively manufactured,
simulations that assess the efficacy of the customized CPAP masks
are vetted by the described methods can be compared to those
simulations that assess the efficacy of the solutions that are
derived from the generative goal statements. Importantly, machine
learning can be harnessed to enhance the efficacy of the described
techniques over time. For example, where the described techniques
are implemented by a computer, the computer can retain data from
previous implementations of the technique and use any of a variety
of known machine learning algorithms to become more efficient at
the described techniques moving forward.
[0072] In numerous embodiments, algorithms for assessing the
efficacy of the simulated designs are determined, and this aspect
is now discussed below.
Determining the Algorithms for Assessing the Efficacy of Each of
the Simulations
[0073] In many embodiments, algorithms for assessing the efficacy
of each of the numerous simulations are determined. In many
embodiments, the algorithms account for the developed robust model.
In many embodiments, the algorithms output an efficacy score. In
numerous embodiments, the algorithms themselves are scored in terms
of relative importance. In a number of embodiments, each algorithm
is assigned a unique identifier, and assigned to an agent. The
algorithms are then delivered to each simulation. As alluded to
above, in some instances certain of the simulations can fail; the
established redundancies can thereby help buffer against such lost
data. With the efficacy algorithms delivered to each simulation,
the efficacy algorithms can then be implemented, and this aspect is
now discussed below.
Assessing the Efficacy of the Simulated Designs
[0074] In many embodiments, the efficacy of each of the simulations
is assessed using the determined algorithms. As mentioned above, in
many embodiments, the efficacy algorithms output a numerical score
corresponding to the measured efficacy. Accordingly, each algorithm
can be implemented on each simulation. Where there are multiple
algorithms, each algorithm can be assigned a relative weight, so
that an overall score for each simulation can be computed. In this
way, an overall efficacy score can be computed for each simulation.
Of course, it should be understood that while efficacy algorithms
are mentioned as a way of evaluating the simulated designs, any
suitable method for measuring the efficacy of the simulated designs
can be implemented. Having scored the efficacy of the designs, a
narrowed set of designs can then be determined and this aspect is
now discussed below.
Converging on a Design
[0075] In many embodiments, at least one design is established as
the most viable. The at least one design can be based on the
efficacy assessments. In several embodiments, a set of designs are
established; when a set of designs are established, a human can
elect which of the set is most desirable. In many embodiments,
designs that are concluded from `generative` goal statements are
deemed entirely unviable/unrealistic, and a filter is applied to
eliminate these designs. The filter can be computational, or it can
be a human. In some embodiments, at least one deterministic design
is established, and at least one generative design is established.
A human can then elect which of the at least one deterministic
design and the at least one generative design is most viable. In
some embodiments, none of the designs are established as
sufficiently viable, and the method is re-run; the re-run method
can take advantage of any applied machine-learning algorithms.
[0076] Once a sufficiently viable design is converged upon, the
product can be additively manufactured in accordance with the
design characteristics, and this aspect is now discussed below.
Additively Manufacturing the Desired Product in Accordance with the
Computed Desired Design Characteristics
[0077] In many embodiments, the desired product is additively
manufactured in accordance with the computed design
characteristics. Any of a variety of additive manufacturing
techniques can be implemented in accordance with embodiments of the
invention. Thus, for instance, in some embodiments, conventional
additive manufacturing techniques are implemented whereby
successive layers of material that represent cross-sections of the
object are deposited, or otherwise formed; generally, the deposited
layers of material fuse (or otherwise solidify) to form the final
object. In many embodiments, additive manufacturing techniques that
allow for greater versatility in manufacture are implemented. For
instance, in many embodiments, 6-axis 3D Printers are used to
additively manufacture the desired object. 6-axis 3D printers are
characterized in that they can deposit constituent material at any
of a variety of angles. In other words, whereas conventional
additive manufacturing apparatuses typically have build heads
(responsible for the deposition of the constituent material) that
only have 3 degrees of freedom, the build head of a 6-axis 3D
printer is characterized by 6 degrees of freedom. This greater
versatility can allow for the desired product to be more
efficiently manufactured, and can allow the final product to be
more structurally integral. For instance, 6-axis 3D printers can
deposit strands of material in a continuous fashion, at any angle,
as opposed to having to repeatedly raster across a build surface to
build up the strand by iteratively depositing cross-sections of the
strand. FIGS. 2A-2D illustrate the additive manufacture of strands
of material, both vertically and at an angle, using 6-axis 3D
printers relative to using conventional 3D printers. In particular,
FIG. 2A illustrates a build head 202 of a 6-axis 3D printer being
used to continuously deposit a strand of material vertically; while
FIG. 2B illustrates a build head 204 of a 6-axis 3D printer being
used to continuously deposit a strand of material at an angle.
FIGS. 2C and 2D, by contrast, illustrate the corresponding
scenarios using conventional 3D printers. In particular, FIG. 2C
illustrates the build head 206 of a conventional 3D Printer being
used to deposit a vertical strand of material. The arrows in FIG.
2C indicate the conventional rastering pattern. Similarly, FIG. 2D
illustrates the deposition of a strand of material at an angle
using a conventional build head 208. As before, the arrows are
suggestive of the rastering pattern. Note that FIGS. 2C and 2D
depict separately deposited cross-sections of material that are
meant to bond after the deposition. This delay in bonding may cause
the respective strands to be less structurally integral relative to
if the strands were continuously deposited along their respective
lengths, e.g. as a 6-axis 3D printer is adept at doing. As a
result, the integrity of the strand can be compromised. In general,
the implementation of 6-axis 3D printers can be particularly useful
where the additive manufacture of the product includes depositing
strands of material.
[0078] For example, the use of 6-axis 3D printing techniques can be
particularly suitable where the desired product is characterized by
a Voronoi structure' that includes linking elements that adopt any
of a variety of orientations. A Voronoi structure can be understood
to be a 3D embodiment of a lattice based on a 3D Voronoi diagram
including links, nodes, and optional interstitial material. Voronoi
structures can be implemented to fabricate any of a variety of
products, and they can be implemented so as to confer any of a
variety of structural characteristics. For example, Voronoi
structures can be made to implement a variation in the regional
elasticity of a product to be fabricated. For instance, FIGS. 3A-3D
depict different lattice structures that can be implemented to
implement different elastic characteristics. In particular, FIG. 3A
depicts a lattice structure 302 characterized by repeating
rectangular cells 304. FIG. 3B depicts a lattice structure 306
characterized by offset rectangular cells 308. FIG. 3C depicts a
lattice structure 310 characterized by trapezoidal cells 312 and
triangular cells 314. And FIG. 3D depicts a lattice structure 316
characterized by irregular cells 318. As can be appreciated these
structures can each manifest different elastic characteristics. In
this way, different elastic characteristics can be implemented in
the customized product by varying the Voronoi structure--e.g.
different portions of the product can be fabricated with different
Voronoi structures. It should of course be realized that these are
not the only lattice structures that can be implemented. Any of a
variety of lattice structures can be implemented in accordance with
embodiments of the invention. As can be appreciated, the particular
lattice structure implemented can be converged on in accordance
with the above-described techniques. More generally, as can be
gathered from the above-discussion, any of a variety of materials
properties--not just the elastic characteristics--can be
manipulated in any of a variety of ways in accordance with
embodiments of the invention. Additionally, any of a variety of
additive manufacturing techniques can be implemented to control the
additive manufacture of the product.
[0079] For example, as mentioned above, the active deposition
techniques described in U.S. patent application Ser. No. 14/321,046
("the '046 application"), incorporated by reference above in its
entirety, can be implemented so as to additively manufacture the
desired product. These techniques can be particularly appropriate
where the product is meant to include varied materials properties
within its structure, as active deposition techniques can
efficiently and effectively allow for the fabrication of structures
having varying localized material characteristics. Notably, active
deposition techniques can be used to vary any of a variety of
materials properties. Importantly, any of the active deposition
techniques disclosed in the '046 application, including those
characterized by claims 20-30 of the as-filed application, can be
implemented in accordance with embodiments of the invention.
Briefly, the active deposition techniques described in the '046
application generally involve fabricating an object by:
progressively depositing constituent material onto a surface to
form the shape of the object to be fabricated in accordance with an
additive manufacturing process; and manipulating the material
properties of at least some portion of the constituent material
that is deposited onto a surface such that at least some portion of
the deposited constituent material possess different material
properties than at least some other portion of the deposited
constituent material; where manipulating the material properties of
the at least some portion of the constituent material begins prior
to, or concurrently with, its deposition onto a surface. As more
thoroughly discussed in the '046 application, the material
properties can be manipulated using any suitable technique such as
one of: subjecting the at least some portion of the constituent
material to electromagnetic waves; magnetizing the at least some
portion of the constituent material; subjecting the at least some
portion of the constituent material to a gas; vibrating the at
least some portion of the constituent material; and heating the at
least some portion of the constituent material. In some
embodiments, implemented active deposition techniques can involve
manipulating the cross-section of the deposited material as it is
being deposited. Again, these techniques are more thoroughly
elaborated on in the '046 application, which is incorporated by
reference in its entirety, especially as it pertains to the
disclosure of active deposition techniques.
[0080] In many embodiments, the investment molding techniques
described in U.S. patent application Ser. No. 14/173,549 ("the '549
application"), incorporated by reference above, are used to
additively manufacture the desired product in accordance with the
computed design characteristics. These techniques can allow for the
efficient fabrication of more intricate geometries. Briefly,
investment molding fabrication techniques generally involve:
fabricating a subassembly comprising a plurality of volumes; where
each volume is defined by the homogenous presence or absence of a
material; where fabricating the subassembly comprises using an
additive manufacturing process; where at least one of the plurality
of volumes defines a shape that is to exist in the object to be
fabricated; where at least a first of the plurality of volumes
comprises a first dissolvable material; dissolving the first
dissolvable material; where the dissolution of the first
dissolvable material does not dissolve at least one other material
within the subassembly; forming at least one cavity within the
subassembly; and introducing an additive material into the at least
one cavity. These techniques can be advantageously used to
fabricate any of a variety of structures such as a CPAP coupling as
seen in FIGS. 5A-5L of the '549 application and/or a shoe, as seen
in FIGS. 6A-6G. Again, these techniques are more thoroughly
elaborated in the '549 application which is incorporated by
reference in its entirety, especially as it pertains to investment
molding techniques including those depicted in, and described with
respect to, FIGS. 5A-5L and FIGS. 6A-6G.
[0081] Examples of the fabrication of customized products in
accordance with embodiments of the invention are now discussed
below.
Additively Manufacturing a Customized Shoe
[0082] In many embodiments, techniques for additively manufacturing
a highly customized shoe are implemented. Thus, for example, the
structure of the shoe can be tailored so as to account for a
particular individual's foot structure, the intended use of the
shoe (e.g. athletics or casual wear), the individual's desired
support/comfort balance, and the intended user's stride/gait.
Accordingly, this information can be obtained prior to the additive
manufacture of the shoe and can be used to inform the final design
characteristics of the shoe. For instance, a pressure map can be
obtained that characterizes the localized pressure exerted/felt by
the user through his/her feet as he/she is standing, e.g. by having
the individual stand on a platform that is designed to characterize
the pressure exerted. FIG. 4 illustrates a pressure map obtained in
accordance with certain embodiments of the invention. In
particular, the illustrated pressure map 402 indicates the force
exerted by each point of the foot. More specifically, the
illustrated pressure map 402 indicates that relatively greater
pressure is exerted by areas corresponding with the big toe 404,
the ball of the foot 406, the heel 408, and relatively less
pressure is exerted by the arch 410 and the smaller toes 412. This
can inform the design of the shoe insofar as it indicates where it
may be desirable to provide more padding. Thus for instance, the
shoe can be additively manufactured to include more padding at the
areas where relatively greater force is exerted. This can vary
amongst individuals, and the ability to so customize a shoe can
thereby be greatly valuable.
[0083] The obtained pressure map information can then be used to
compute the desired design characteristics of shoe, e.g. using the
above-described processes. In many embodiments, the end product is
manifested via a Voronoi structure. Where a Voronoi structure is to
be implemented, a computer can compute the Voronoi design--e.g.
where the links/nodes are to exist--using the provided data. Thus,
FIGS. 5A-5C illustrate Voronoi designs computed in view of the
provided pressure map. In particular, the computed Voronoi designs
conclude a greater number of nodes at the ball of the foot, the big
toe, and the heel, which corresponds to the creation of a stiffer
material/more support at these points. Notably, the computations
that resulted in the Voronoi design depicted in FIG. 5A can be
iterated so as to smooth out the design, e.g. using Lloyd's
algorithm. FIGS. 5B and 5C depict progressively more relaxed
Voronoi designs that have less disparity in node density across the
shoe. While FIGS. 5A-5C depict Voronoi designs that are computed
using provided pressure map data, in many embodiments, the
computation of the designs accounts for additional information,
such as the particular individual's stride/gait. In general, the
computation of the design characteristics of the shoe can account
for any of a variety of--and any number of--considerations in
accordance with embodiments of the invention.
[0084] FIGS. 6A-6B depict the fabricated shoe. In particular, FIG.
6A depicts a side view of the shoe, and FIG. 6B depicts the sole of
the shoe. Note that the sole of the shoe implements the computed
Voronoi structure. While the entire shoe can be additively
manufactured, in many embodiments, only the portion(s) of the shoe
that most benefit from high customization are additively
manufactured. Thus, for example, in many embodiments, only the sole
of the shoe is additively manufactured. The remaining portions of
the shoe can be fabricated using any suitable technique.
[0085] As can be appreciated the above described techniques for
fabricating highly customized products are general and can be
implemented in any of a variety of ways, and can be used to
fabricate any of a variety of products and not just shoes. Thus,
for instance, the techniques can be used to additively manufacture
a highly customized `shaper,` and this aspect is now discussed
below.
Additively Manufacturing a Shaper
[0086] In many embodiments, techniques for additively manufacturing
a highly customized shaper are implemented. For example, in a
number of embodiments, highly customized muscle shirts are
fabricated that are meant to accentuate the contours of an
individual's muscles. In several embodiments, articles of wear are
fabricated that are meant to deform an individual's body into a
more aesthetically pleasing form. As can be gleaned from the above
discussion, the above described generalized techniques can be
implemented in the fabrication of these articles of wear. Thus, for
instance, where a highly customized `muscle shirt` is desired, a 3D
scan of the intended wearer's body can be obtained and used in the
computation of the muscle shirt's final design characteristics.
Additionally, in many embodiments, the individual's subcutaneous
structure is also obtained, e.g. via thermal imaging. This
information can also be used to compute how best to accentuate the
individual's muscular structure. FIGS. 7A and 7B illustrate a
target individual's body relative to the desired contours.
[0087] With the obtained information, the design characteristics of
the muscle shirt can be computed, e.g. the above described
computation techniques can be implemented. For example, the shirt
can be fabricated so as to encourage the repositioning of fat
tissue into areas of the body associated with muscular definition.
FIGS. 8A and 8B depict the additively manufactured muscle shirt.
Note that the additive manufacture of the shirt can be accomplished
using any suitable technique. In many embodiments, thermoset fibers
are printed onto a base material, which can be any of a variety of
materials including nylon, polyester, or other synthetic material.
The density of and positioning of the fibers can inform the elastic
characteristics of the muscle shirt. In several embodiments, layers
of thermoset materials are implemented.
[0088] Again, it should be reiterated that the above-described
techniques are general and can be implemented in any of a variety
of ways. Thus, for example, while a muscle shirt has been discussed
above, in many embodiments, a woman's bra is fabricated. Thus,
FIGS. 9A-9B illustrate how a highly customized women's bra can be
used to elevate a particular woman's breasts. In particular, FIG.
9A illustrates the desired effect of the woman's bra, i.e. to
elevate the breasts. FIG. 9B illustrates the fabricated bra. The
different portions of the bra, 904, 906, 908, reflect areas of
different elasticity that are used to reposition the woman's
breasts in the desired manner.
[0089] While articles of wear that rely on customized elastic
characteristics to promote a more aesthetically pleasing figure
have been discussed, in many embodiments the ability to vary the
elasticity across an article of wear is used for other purposes.
For instance, in some embodiments, an athletic shirt having varying
elastic characteristics that allows the wearer to advantageously
harness the elastic energy that is stored when the shirt is
stretched. Thus for instance, such an athletic shirt can be
customized for a baseball pitcher, such that when the baseball
pitcher `winds up` to pitch the ball, the highly customized elastic
characteristics of the athletic shirt will encourage the proper
form in releasing the pitch. In some embodiments, an article of
wear is customized to add elastic resistance to any of a variety of
predefined movements. In effect, the article of wear can thereby
facilitate resistance training. In a number of embodiments, an
article of wear that provides for customized padding is
implemented.
[0090] Again, as can be appreciated, the above described techniques
are general and can be used to fabricate any of a variety of
shapers. More generally, the techniques can be used to fabricate
any of a variety of products. The fabrication of a highly
customized CPAP mask tailored to a particular individual is now
described in greater detail below.
Additively Manufacturing Highly Customized CPAP Masks
[0091] In many embodiments, the above-described generalized
techniques are implemented so as to fabricate a highly-customized
CPAP mask tailored for a particular individual. Discomfort is often
cited as an issue when people elect not to don prescribed CPAP
masks. Accordingly, many embodiments provide for highly tailored
CPAP masks to make their use more comfortable and promote an
individual's wellbeing. Accordingly, in many embodiments, a 3D
structure of the target individual's facial geometry is obtained.
As alluded to above, this can be obtained using any of a number of
techniques, including 3D scanning. In numerous embodiments, the
subcutaneous structure of the target individual's facial structure
is also obtained. This can be obtained, e.g. via thermal imaging.
FIGS. 10A-10F illustrate an acquired thermal images of a target
individual's facial structure that conveys the target individual's
subcutaneous structure as well as images reflecting the
computations performed. In particular, FIG. 10A illustrates a raw
thermal scan obtained in accordance with certain embodiments of the
invention. FIG. 10B illustrates the creation of geometric zones
characterizing the facial structure in acc. FIG. 10C illustrates
data computed concerning where the CPAP mask should relatively more
or less elastic in accordance with certain embodiments of the
invention. FIG. 10D illustrates the visualized data mapped to a hex
graph in accordance with certain embodiments of the invention. FIG.
10E illustrates the defining of attractor points in accordance with
certain embodiments of the invention. And FIG. 1OF illustrates the
concluded mask design in accordance with certain embodiments of the
invention.
[0092] As before, the obtained data can be used to derive the
desired design characteristics. For example, the subcutaneous
structure information can be used to configure the coupling so as
to minimize discomfort. Additionally, the facial/nostril geometry
can be used to facilitate a laminar flow through the mask. The CPAP
mask can then be fabricated so as to implement the desired design
characteristics. Any suitable additive manufacturing technique can
be implemented including any of the above-described techniques.
FIGS. 11A-11E depict the additively manufactured CPAP mask. In
particular, FIG. 11A depicts the CPAP mask 1102, and also
highlights how different areas of the mask 1104 and 1106 have
differently oriented fibers that are associated together at
different densities. The different orientations and different fiber
densities can allow for different elastic characteristics.
Accordingly, the fitting of the mask for a particular user can be
controlled.
[0093] FIG. 11B illustrates a cut-away of the CPAP mask 1102 that
shows the air ducts 1108 that can be additively manufactured within
the mask. As can be appreciated, the particular air duct structure
can be customized based on the desired needs. In many embodiments,
the air ducts include rifling features to facilitate desired
airflow. The rifling features can be implemented macroscopically,
e.g. by controlling the macroscopic structure of the air ducts. In
several embodiments, rifling features are implemented on a smaller
scale, and this can be achieved by controlling the 3D printer's
tooling path as it deposits constituent material. For example, this
can have the effect of influencing the orientation of the deposited
`strands of material`, and this control of orientation can be used
to help control the air flow.
[0094] FIG. 11C illustrates the interior of the CPAP mask 1102
including the nasal tubes. As can be appreciated, nasal passages
are intricate features and it is important that the tubes be
manufactured to fit snuggly within the nostrils. In many
embodiments, the elasticity of the nasal tubes is configured so
that when air is blowing through them via the individual's normal
breathing pattern, the tube conforms to the contours of the
nostrils. FIG. 11D illustrates the nasal fitting within the nostril
without pressurization, and FIG. 11E illustrates how the tube
conforms to the nostril as a result of the continuous pressure from
CPAP mask. When the nasal tube expands, it effectively seals the
gap between the tube and the nostril, thereby forcing the air from
the CPAP into the patient's nasal cavity with little or no
leakage.
[0095] While the above description is relatively generalized, it
should of course be realized that the generalized techniques can be
implemented in any of a variety of ways in accordance with
embodiments of the invention. Thus, it is discussed below, a
process listing some of the nuances that can be implemented in
accordance with certain embodiments of the invention is listed
below.
Process for Additively Manufacturing Customized
[0096] As can be appreciated, the discussed methodologies for
fabricating highly customized products using computational methods
can be implemented in any of a variety of ways in accordance with
embodiments of the invention. For example, FIG. 12 depicts a flow
chart that indicates a number of nuances that can be implemented in
accordance with embodiments of the invention. In general, the
process depicts the data capture and aggregation, the
parameterization, simulation/evaluation, optimization, and
fabrication for a process for fabricating a highly customized part
in accordance with embodiments of the invention. In particular, the
depicted process lists some of the nuances associated with each of
the broader implemented techniques. For example, the depicted
process illustrates that data capture and aggregation can include
obtaining some combination of: geometric data, kinematic data,
sub-coetaneous data, acoustic data, and other bio data. This data
can be composited, with gaps being inferred and filled, and this
manipulation being used to compute, e.g., a finite element
analysis, which is then used to derive a robust anthropomorphic
model. Similarly, the illustrated process depicts that
parameterization can involve user inputted deterministic (product)
and generative goals (`use case`). The computations can include
applying the anthropomorphic model to the use case, and this
aggregate can thereby be used to establish variables. The
illustrated process also depicts some of the nuances that can be
present in parallelizing the data, simulating/evaluating the data,
optimizing the data, and fabricating the product. Note that the
illustrated process also depicts that machine learning algorithms
can be implemented and used to inform the parameterization process
as well as the parallelization process. In this way, where methods
are substantially performed on a single computational system, the
computational system can become more efficient and efficacious over
time. As can be appreciated, the above illustrated process is meant
to be one example of how the above-described general processes can
be implemented. It should of course be understood, that the
above-described processes can be implemented in any of a variety of
ways, and can be nuanced in any of a variety of ways in accordance
with embodiments of the invention.
[0097] More generally, as can be inferred from the above
discussion, any of the above-mentioned concepts can be implemented
in a variety of arrangements in accordance with embodiments of the
invention. For example, as can be appreciated by one of ordinary
skill in the art, the sequence of many of the techniques applied in
the above-described methods can be varied in any of a variety of
ways. Accordingly, although the present invention has been
described in certain specific aspects, many additional
modifications and variations would be apparent to those skilled in
the art. It is therefore to be understood that the present
invention may be practiced otherwise than specifically described.
Thus, embodiments of the present invention should be considered in
all respects as illustrative and not restrictive.
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