Computer aided generative design with layer boundary determination to facilitate 2.5-axis subtractive manufacturing processes

1 . A method comprising:

obtaining, by a computer program, one or more design criteria for a modeled object, for which a corresponding physical structure is to be manufactured using a 2.5-axis subtractive manufacturing process;

iteratively modifying, by the computer program, a three-dimensional shape of the modeled object in accordance with the one or more design criteria;

defining layer boundaries between three or more discrete layers for the three-dimensional shape based on differences among multiple milling depths identified for respective milling lines in a density-based representation of the three-dimensional shape, wherein each of the milling lines is parallel to a milling direction of the 2.5-axis subtractive manufacturing process and comprises a subset of individual elements in the density-based representation of the three-dimensional shape of the modeled object, each of the three or more discrete layers is perpendicular to the milling direction of the 2.5-axis subtractive manufacturing process, and the defining comprises adjusting the density-based representation of the three-dimensional shape to reassign milling depths for at least a portion of the milling lines by changing density values of individual elements located in the at least a portion of the milling lines such that a single milling depth is produced for each of the layer boundaries between the three or more discrete layers for the three-dimensional shape, thereby changing the three-dimensional shape of the modeled object; and

providing, by the computer program, the three-dimensional shape of the modeled object for use in manufacturing a physical structure corresponding to the modeled object using one or more computer-controlled manufacturing systems that employ the 2.5-axis subtractive manufacturing process.

2 . The method of claim 1 , wherein the adjusting is performed during at least two iterations of the iteratively modifying.

3 . The method of claim 1 , wherein the adjusting comprises:

collecting the multiple milling depths associated with different subsets of individual elements in the density-based representation of the three-dimensional shape of the modeled object;

grouping the multiple milling depths into respective ones of the three or more discrete layers; and

changing density values for at least a portion of the individual elements in the density-based representation such that a single milling depth is produced for each of the three or more discrete layers.

4 . The method of claim 3 , wherein the grouping comprises:

sorting the multiple milling depths to produce sorted milling depth values;

identifying two or more largest differences in the sorted milling depth values;

assigning each of the different subsets of the individual elements to one of the three or more discrete layers based on a position of each subset's milling depth within the sorted milling depth values in relation to the two or more largest differences; and

setting the single milling depth in each respective discrete layer of the three or more discrete layers based on milling depths associated with element subsets assigned to the discrete layer.

5 . The method of claim 3 , wherein the collecting comprises:

arranging individual elements in the density-based representation of the three-dimensional shape into the milling lines parallel to the milling direction;

aggregating densities of elements along each of the milling lines such that the aggregated densities of the elements monotonically increase along each of the milling lines; and

identifying a milling depth for each of the milling lines using the aggregated densities in each of the milling lines.

6 . The method of claim 1 , wherein the milling direction is a first of two or more milling directions of the 2.5-axis subtractive manufacturing process, and the adjusting is performed separately for each of the two or more milling directions to define layer boundaries of different discrete layers for each respective milling direction.

7 . The method of claim 1 , wherein the adjusting is performed after the iteratively modifying.

8 . The method of claim 1 , wherein the obtaining comprises obtaining one or more in-use cases for the physical structure, and the iteratively modifying comprises iteratively modifying a three-dimensional topology of the modeled object in accordance with the one or more design criteria and the one or more in-use cases.

9 . The method of claim 8 , wherein the iteratively modifying produces new three-dimensional geometry that connects input preserve solids.

10 . The method of claim 9 , comprising determining a number of the three or more discrete layers.

11 . The method of claim 10 , wherein determining the number of the three or more discrete layers comprises determining the number within a range of numbers of layers provided by a user.

12 . The method of claim 10 , wherein determining the number of the three or more discrete layers comprises dividing layers until a minimum difference in a gap between two layers is less than a user-provided threshold.

13 . The method of claim 10 , wherein determining the number of the three or more discrete layers comprises determining one or more planes between discrete layers based on the input preserve solids.

14 . A system comprising:

a non-transitory storage medium having instructions of a computer aided design program stored thereon; and

one or more data processing apparatus configured to run the instructions of the computer aided design program to cause the one or more data processing apparatus to

obtain one or more design criteria for a modeled object, for which a corresponding physical structure is to be manufactured using a 2.5-axis subtractive manufacturing process,

iteratively modify a three-dimensional shape of the modeled object in accordance with the one or more design criteria,

define layer boundaries between three or more discrete layers for the three-dimensional shape based on differences among multiple milling depths identified for respective milling lines in a density-based representation of the three-dimensional shape, wherein each of the milling lines is parallel to a milling direction of the 2.5-axis subtractive manufacturing process and comprises a subset of individual elements in the density-based representation of the three-dimensional shape of the modeled object, each of the three or more discrete layers is perpendicular to the milling direction of the 2.5-axis subtractive manufacturing process, wherein the one or more data processing apparatus define the layer boundaries by being configured to run the instructions of the computer aided design program to cause at least adjusting the density-based representation of the three-dimensional shape to reassign milling depths for at least a portion of the milling lines by changing density values of individual elements located in the at least a portion of the milling lines such that a single milling depth is produced for each of the layer boundaries between the three or more discrete layers for the three-dimensional shape, thereby changing the three-dimensional shape of the modeled object, and

provide the three-dimensional shape of the modeled object for use in manufacturing a physical structure corresponding to the modeled object using one or more computer-controlled manufacturing systems that employ the 2.5-axis subtractive manufacturing process.

15 . The system of claim 14 , wherein the adjusting is performed during at least two iterations of the iteratively modifying.

16 . The system of claim 14 , wherein the adjusting comprises:

collecting the multiple milling depths associated with different subsets of individual elements in the density-based representation of the three-dimensional shape of the modeled object;

grouping the multiple milling depths into respective ones of the three or more discrete layers; and

changing density values for at least a portion of the individual elements in the density-based representation such that a single milling depth is produced for each of the three or more discrete layers.

17 . The system of claim 16 , wherein the grouping comprises:

sorting the multiple milling depths to produce sorted milling depth values;

identifying two or more largest differences in the sorted milling depth values;

assigning each of the different subsets of the individual elements to one of the three or more discrete layers based on a position of each subset's milling depth within the sorted milling depth values in relation to the two or more largest differences; and

setting the single milling depth in each respective discrete layer of the three or more discrete layers based on milling depths associated with element subsets assigned to the discrete layer.

18 . The system of claim 16 , wherein the collecting comprises:

arranging individual elements in the density-based representation of the three-dimensional shape into the milling lines parallel to the milling direction;

aggregating densities of elements along each of the milling lines such that the aggregated densities of the elements monotonically increase along each of the milling lines; and

identifying a milling depth for each of the milling lines using the aggregated densities in each of the milling lines.

19 . The system of claim 14 , wherein the milling direction is a first of two or more milling directions of the 2.5-axis subtractive manufacturing process, and the adjusting is performed separately for each of the two or more milling directions to define layer boundaries of different discrete layers for each respective milling direction.

20 . The system of claim 14 , wherein the adjusting is performed after the iterative modification of the three-dimensional shape of the modeled object in accordance with the one or more design criteria.

21 . The system of claim 14 , wherein the one or more data processing apparatus are configured to run the instructions of the computer aided design program to cause the one or more data processing apparatus to

obtain one or more in-use cases for the physical structure, and

perform the iterative modification of the three-dimensional shape of the modeled object in accordance with the one or more design criteria and the one or more in-use cases.

22 . The system of claim 21 , wherein the iterative modification of the three-dimensional shape of the modeled object produces new three-dimensional geometry that connects input preserve solids.

23 . The system of claim 22 , wherein the one or more data processing apparatus are configured to run the instructions of the computer aided design program to cause the one or more data processing apparatus to determine a number of the three or more discrete layers.

24 . The system of claim 23 , wherein the one or more data processing apparatus are configured to run the instructions of the computer aided design program to cause the one or more data processing apparatus to determine the number within a range of numbers of layers provided by a user.

25 . The system of claim 23 , wherein the one or more data processing apparatus are configured to run the instructions of the computer aided design program to cause the one or more data processing apparatus to divide layers until a minimum difference in a gap between two layers is less than a user-provided threshold.

26 . The system of claim 23 , wherein the one or more data processing apparatus are configured to run the instructions of the computer aided design program to cause the one or more data processing apparatus to determine one or more planes between discrete layers based on the input preserve solids.

27 . The system of claim 14 , comprising a computer numerically controlled subtractive manufacturing milling machine that employ the 2.5-axis subtractive manufacturing process.

28 . The system of claim 27 , wherein the computer numerically controlled subtractive manufacturing milling machine comprises a 3-axis or multi-axis subtractive manufacturing milling machine.

29 . A non-transitory computer-readable medium tangibly encoding a computer program operable to cause data processing apparatus to perform operations comprising:

obtaining one or more design criteria for a modeled object, for which a corresponding physical structure is to be manufactured using a 2.5-axis subtractive manufacturing process;

iteratively modifying a three-dimensional shape of the modeled object in accordance with the one or more design criteria;

defining layer boundaries between three or more discrete layers for the three-dimensional shape based on differences among multiple milling depths identified for respective milling lines in a density-based representation of the three-dimensional shape, wherein each of the milling lines is parallel to a milling direction of the 2.5-axis subtractive manufacturing process and comprises a subset of individual elements in the density-based representation of the three-dimensional shape of the modeled object, each of the three or more discrete layers is perpendicular to the milling direction of the 2.5-axis subtractive manufacturing process, and the defining comprises adjusting the density-based representation of the three-dimensional shape to reassign milling depths for at least a portion of the milling lines by changing density values of individual elements located in the at least a portion of the milling lines such that a single milling depth is produced for each of the layer boundaries between the three or more discrete layers for the three-dimensional shape, thereby changing the three-dimensional shape of the modeled object; and

providing the three-dimensional shape of the modeled object for use in manufacturing a physical structure corresponding to the modeled object using one or more computer-controlled manufacturing systems that employ the 2.5-axis subtractive manufacturing process.

30 . The non-transitory computer-readable medium of claim 29 , wherein the adjusting is performed during at least two iterations of the iteratively modifying.

31 . The non-transitory computer-readable medium of claim 29 , wherein the adjusting comprises:

collecting the multiple milling depths associated with different subsets of individual elements in the density-based representation of the three-dimensional shape of the modeled object;

grouping the multiple milling depths into respective ones of the three or more discrete layers; and

changing density values for at least a portion of the individual elements in the density-based representation such that a single milling depth is produced for each of the three or more discrete layers.

32 . The non-transitory computer-readable medium of claim 31 , wherein the grouping comprises:

sorting the multiple milling depths to produce sorted milling depth values;

identifying two or more largest differences in the sorted milling depth values;

assigning each of the different subsets of the individual elements to one of the three or more discrete layers based on a position of each subset's milling depth within the sorted milling depth values in relation to the two or more largest differences; and

setting the single milling depth in each respective discrete layer of the three or more discrete layers based on milling depths associated with element subsets assigned to the discrete layer.

33 . The non-transitory computer-readable medium of claim 31 , wherein the collecting comprises:

arranging individual elements in the density-based representation of the three-dimensional shape into the milling lines parallel to the milling direction;

aggregating densities of elements along each of the milling lines such that the aggregated densities of the elements monotonically increase along each of the milling lines; and

identifying a milling depth for each of the milling lines using the aggregated densities in each of the milling lines.

34 . The non-transitory computer-readable medium of claim 29 , wherein the milling direction is a first of two or more milling directions of the 2.5-axis subtractive manufacturing process, and the adjusting is performed separately for each of the two or more milling directions to define layer boundaries of different discrete layers for each respective milling direction.

35 . The non-transitory computer-readable medium of claim 29 , wherein the adjusting is performed after the iteratively modifying.

36 . The non-transitory computer-readable medium of claim 29 , wherein the obtaining comprises obtaining one or more in-use cases for the physical structure, and the iteratively modifying comprises iteratively modifying a three-dimensional topology of the modeled object in accordance with the one or more design criteria and the one or more in-use cases.

37 . The non-transitory computer-readable medium of claim 36 , wherein the iteratively modifying produces new three-dimensional geometry that connects input preserve solids.

38 . The non-transitory computer-readable medium of claim 37 , wherein the operations comprise determining a number of the three or more discrete layers.

39 . The non-transitory computer-readable medium of claim 38 , wherein determining the number of the three or more discrete layers comprises determining the number within a range of numbers of layers provided by a user.

40 . The non-transitory computer-readable medium of claim 38 , wherein determining the number of the three or more discrete layers comprises dividing layers until a minimum difference in a gap between two layers is less than a user-provided threshold.

41 . The non-transitory computer-readable medium of claim 38 , wherein determining the number of the three or more discrete layers comprises determining one or more planes between discrete layers based on the input preserve solids.