Adaptive material deposition in three-dimensional fabrication

Abstract

The subject disclosure is directed towards adapting a three-dimensional model to surface geometry when fabricating a three-dimensional object. While partitioning model data into planar regions and non-planar regions of the three-dimensional object, the model data associated with the non-planar regions is modified to more accurately generate a path that follows the object's curved surface geometry. This path is transformed into an instruction set, which when executed by a device, causes movement along the path while depositing material on the three-dimensional object.

What is claimed is: 
     
         1 . In a computing environment, a method performed at least in part on at least one processor, comprising, adapting a three-dimensional model to surface geometry when fabricating a three-dimensional object, including, processing model data defining planar regions and non-planar regions of the three-dimensional object, generating an instruction set that comprises instructions corresponding to the non-planar regions, and generating other instructions for the instruction set that correspond to the planar regions. 
     
     
         2 . The method of  claim 1 , wherein generating the instruction set further comprises generating instructions corresponding to three-dimensional movement of an extruder nozzle. 
     
     
         3 . The method of  claim 1  further comprising modifying the model data associated with the non-planar regions. 
     
     
         4 . The method of  claim 3 , wherein modifying the model data further comprises modifying a layer height based upon a curvature of the non-planar regions. 
     
     
         5 . The method of  claim 3 , wherein modifying the model data further comprises modifying a layer height for a portion of a layer. 
     
     
         6 . The method of  claim 1 , wherein generating the instruction set further comprises modifying at least one of a width, a thickness or a length of deposited material. 
     
     
         7 . The method of  claim 1 , wherein generating the instruction set further comprises varying material width to produce texture on a surface. 
     
     
         8 . The method of  claim 1 , wherein generating the instruction set further comprises modifying a material height along tool paths outlining the three-dimensional object. 
     
     
         9 . The method of  claim 1 , wherein modifying the model data further comprises rotating the model data of the non-planar regions along an axis, generating three-dimensional paths for the non-planar regions, and rotating the model data back along the axis. 
     
     
         10 . In a computing environment, a system, comprising, a fabrication device configured to deposit material for producing a three-dimensional object, and a fabrication manager configured to identify a portion of curved surface geometry associated with the three-dimensional object, modify instructions for depositing material along at least one dimension on the portion of the curved surface geometry, and instruct the fabrication device to fabricate the three-dimensional object. 
     
     
         11 . The system of  claim 10 , wherein the fabrication manager is further configured to modify a material width along tool paths between an interior and exterior outline. 
     
     
         12 . The system of  claim 10 , wherein the fabrication manager is further configured to modify model data corresponding to the portion of the curved surface geometry, and to generate an instruction set that when executed, modulates material deposition on the portion of the curved surface geometry. 
     
     
         13 . The system of  claim 10 , wherein the fabrication manager is further configured to define a three-dimensional path for depositing material on the portion of the curved surface geometry, and to generate instructions corresponding to the three-dimensional path, and wherein the fabrication device comprises a controller configured to execute the instructions, causing three-dimensional movement of at least one of a tool head or a movable platform. 
     
     
         14 . The system of  claim 13 , wherein the fabrication device comprises a robot configured to actuate an extruder nozzle along the three-dimensional path. 
     
     
         15 . The system of  claim 10 , wherein the fabrication manager is further configured to partition the curved surface geometry into cross-sections along at least one of an x-axis or a y-axis. 
     
     
         16 . The system of  claim 15 , wherein the fabrication manager is further configured to rotate a cross-section along at least one of an x-dimension, a y-dimension, or a z-dimension, and generate instructions for depositing material on a non-planar region of the cross-section. 
     
     
         17 . The system of  claim 11 , wherein the fabrication manager is further configured to remove non-planar regions of the curved surface geometry from the model data, to generate a set of instructions for fabricating other regions of the three-dimensional object, and to generate another set of instructions for fabricating the non-planar regions. 
     
     
         18 . One or more computer-readable media having computer-executable instructions, which when executed perform steps, comprising:
 partitioning model data corresponding to a three-dimensional object into layers along a dimension in which at least one layer defines a surface geometry;   mapping at least one texture pattern to the surface geometry; and   modifying material deposition based upon the mapping of the at least one texture pattern to the surface geometry.   
     
     
         19 . The one or more computer-readable media of  claim 18  having further computer-executable instructions, which when executed perform steps, comprising:
 modifying at least one of a material thickness or a material width when depositing material on a surface of the three-dimensional object. 
 
     
     
         20 . The one or more computer-readable media of  claim 18  having further computer-executable instructions, which when executed perform steps, comprising:
 determining an extrusion speed and an extrusion feed rate based upon the model data.