US 12,263,641 B2
Mass customization in additive manufacturing
Hardik Kabaria, San Francisco, CA (US); and Aidan Kurtz, Palomar Park, CA (US)
Assigned to CARBON, INC., Redwood City, CA (US)
Appl. No. 17/439,592
Filed by Carbon, Inc., Redwood City, CA (US)
PCT Filed Apr. 29, 2020, PCT No. PCT/US2020/030382
§ 371(c)(1), (2) Date Sep. 15, 2021,
PCT Pub. No. WO2020/223291, PCT Pub. Date Nov. 5, 2020.
Claims priority of provisional application 62/840,736, filed on Apr. 30, 2019.
Prior Publication US 2022/0143917 A1, May 12, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B29C 64/386 (2017.01); B33Y 50/00 (2015.01)
CPC B29C 64/386 (2017.08) [B33Y 50/00 (2014.12)] 18 Claims
OG exemplary drawing
 
1. A method for the rapid production of an object from a light-polymerizable resin by additive manufacturing, comprising:
(a) inputting into a processor a boundary shape and a plurality of desired mechanical properties for said object;
(b) subdividing said boundary shape into a plurality of adjacent work cells in the processor;
(c) providing a plurality of lattices in a database, each lattice of the database including a geometry and a mechanical property;
(d) filling a first one of said work cells with a lattice from the database, the lattice selected based on a correspondence of the mechanical properties of said lattice to said desired mechanical properties of said object;
(e) filling the remaining ones of said work cells with lattices from said database to produce a filled boundary shape in the processor, each said lattice selected based on: (i) the correspondence of the mechanical properties of said lattice to the desired mechanical properties of the object, and (ii) a compatibility of adjacent lattices in adjacent work cells with one another; then
(f) performing a modification operation on the lattice of at least one of the work cells;
wherein said database includes a manufacturability score for said additive manufacturing step for each said lattice, said filling steps (d)-(e) are carried out with preference for lattices having a higher manufacturability score, and the manufacturability score comprises a metric with respect to manufacturing for each said lattice.