Generative design shape optimization with singularities and disconnection prevention for computer aided design and manufacturing

1. A method comprising:

obtaining, by a computer aided design program, a design space for a modeled object, for which a corresponding physical structure will be manufactured, one or more design criteria for the modeled object, and one or more in-use load cases for the physical structure;

iteratively modifying, by the computer aided design program, a generatively designed three dimensional shape of the modeled object in the design space in accordance with the one or more design criteria and the one or more in-use load cases for the physical structure, wherein the iteratively modifying comprises

performing numerical simulation of the modeled object in accordance with a current version of the three dimensional shape and the one or more in-use load cases to produce a current numerical assessment of a physical response of the modeled object,

computing shape change velocities for an implicit surface in a level-set representation of the three dimensional shape,

changing the shape change velocities in accordance with a polynomial function that has been fit to at least a portion of the shape change velocities above a reference velocity,

updating the level-set representation using the shape change velocities to produce an updated version of the three dimensional shape of the modeled object, and

repeating at least the performing, the computing, the changing and the updating until a predefined number of shape modification iterations have been performed or until the generatively designed three dimensional shape of the modeled object in the design space converges to a stable solution for the one or more design criteria and the one or more in-use load cases; and

providing, by the computer aided design program, the generatively designed three dimensional shape of the modeled object for use in manufacturing the physical structure corresponding to the modeled object using one or more computer-controlled manufacturing systems.

2. The method of claim 1 , comprising setting the reference velocity based on a mean and a standard deviation of a shape derivative on the implicit surface.

3. The method of claim 2 , comprising fitting the polynomial function being a cubic polynomial to velocity values above the reference velocity.

4. The method of claim 1 , wherein the iteratively modifying comprises, after the updating and before the repeating:

checking for an excessive change having been made during the updating;

making the current version of the three dimensional shape be the updated version of the three dimensional shape for a next iteration to undue the excessive change; and

slowing shape changes for the next iteration of the iteratively modifying.

5. The method of claim 4 , wherein checking for the excessive change comprises comparing a change in the one or more design criteria resulting from the updating with a predefined limit on an amount of change allowed for the one or more design criteria in a single iteration of the iteratively modifying.

6. The method of claim 5 , wherein slowing the shape changes for the next iteration comprises reducing a target volume change for the generatively designed three dimensional shape of the modeled object for the next iteration of the iteratively modifying.

7. The method of claim 1 , wherein the iteratively modifying comprises, before performing the numerical simulation:

identifying any elements, generated from the current version of the three dimensional shape for the numerical simulation, that are partially but not entirely within the implicit surface; and

removing any of the identified elements that are not connected to any nodes of the current version of the three dimensional shape with Dirichlet boundary conditions, before performing the numerical simulation.

8. The method of claim 1 , wherein the iteratively modifying comprises, before performing the numerical simulation:

identifying any elements, generated from the current version of the three dimensional shape for the numerical simulation, that are partially but not entirely within the implicit surface; and

setting densities of the identified elements equal to respective volume fractions of the identified elements, wherein a volume fraction of an identified element is a fractional amount of the identified element that falls within the implicit surface;

wherein performing the numerical simulation includes penalizing stiffness of the identified elements according to the densities.

9. 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:

obtain a design space for a modeled object, for which a corresponding physical structure will be manufactured, one or more design criteria for the modeled object, and one or more in-use load cases for the physical structure;

iteratively modify a generatively designed three dimensional shape of the modeled object in the design space in accordance with the one or more design criteria and the one or more in-use load cases for the physical structure, wherein the one or more data processing apparatus are configured to run the instructions of the computer aided design program to iteratively modify the generatively designed three dimensional shape of the modeled object by being configured to run the instructions of the computer aided design program to

perform numerical simulation of the modeled object in accordance with a current version of the three dimensional shape and the one or more in-use load cases to produce a current numerical assessment of a physical response of the modeled object,

compute shape change velocities for an implicit surface in a level-set representation of the three dimensional shape,

change the shape change velocities in accordance with a polynomial function that has been fit to at least a portion of the shape change velocities above a reference velocity,

update the level-set representation using the shape change velocities to produce an updated version of the three dimensional shape of the modeled object, and

repeat at least the performing, the computing, the changing and the updating until a predefined number of shape modification iterations have been performed or until the generatively designed three dimensional shape of the modeled object in the design space converges to a stable solution for the one or more design criteria and the one or more in-use load cases; and

provide, by the computer aided design program, the generatively designed three dimensional shape of the modeled object for use in manufacturing the physical structure corresponding to the modeled object using one or more computer-controlled manufacturing systems.

10. The system of claim 9 , comprising an additive manufacturing machine, wherein the one or more data processing apparatus are configured to run the instructions of the computer aided design program to generate toolpath specifications for the additive manufacturing machine from the three dimensional model, and manufacture the physical structure corresponding to the object with the additive manufacturing machine using the toolpath specifications.

11. The system of claim 9 , wherein the one or more data processing apparatus are configured to run the instructions of the computer aided design program to set the reference velocity based on a mean and a standard deviation of a shape derivative on the implicit surface.

12. A non-transitory computer-readable medium encoding a computer aided design program operable to cause one or more data processing apparatus to perform operations comprising:

obtaining, by a computer aided design program, a design space for a modeled object, for which a corresponding physical structure will be manufactured, one or more design criteria for the modeled object, and one or more in-use load cases for the physical structure;

iteratively modifying, by the computer aided design program, a generatively designed three dimensional shape of the modeled object in the design space in accordance with the one or more design criteria and the one or more in-use load cases for the physical structure, wherein the iteratively modifying comprises

performing numerical simulation of the modeled object in accordance with a current version of the three dimensional shape and the one or more in-use load cases to produce a current numerical assessment of a physical response of the modeled object,

computing shape change velocities for an implicit surface in a level-set representation of the three dimensional shape,

changing the shape change velocities in accordance with a polynomial function that has been fit to at least a portion of the shape change velocities above a reference velocity,

updating the level-set representation using the shape change velocities to produce an updated version of the three dimensional shape of the modeled object, and

repeating at least the performing, the computing, the changing and the updating until a predefined number of shape modification iterations have been performed or until the generatively designed three dimensional shape of the modeled object in the design space converges to a stable solution for the one or more design criteria and the one or more in-use load cases; and

providing, by the computer aided design program, the generatively designed three dimensional shape of the modeled object for use in manufacturing the physical structure corresponding to the modeled object using one or more computer-controlled manufacturing systems.

13. The non-transitory computer-readable medium of claim 12 , wherein the operations comprise setting the reference velocity based on a mean and a standard deviation of a shape derivative on the implicit surface.

14. The non-transitory computer-readable medium of claim 13 , wherein the operations comprise fitting the polynomial function being a cubic polynomial to velocity values above the reference velocity.

15. The non-transitory computer-readable medium of claim 13 , wherein the iteratively modifying comprises, after the updating and before the repeating:

checking for an excessive change having been made during the updating;

making the current version of the three dimensional shape be the updated version of the three dimensional shape for a next iteration to undue the excessive change; and

slowing shape changes for the next iteration of the iteratively modifying.

16. The non-transitory computer-readable medium of claim 15 , wherein checking for the excessive change comprises comparing a change in the one or more design criteria resulting from the updating with a predefined limit on an amount of change allowed for the one or more design criteria in a single iteration of the iteratively modifying.

17. The non-transitory computer-readable medium of claim 15 , wherein slowing the shape changes for the next iteration comprises reducing a target volume change for the generatively designed three dimensional shape of the modeled object for the next iteration of the iteratively modifying.

18. The non-transitory computer-readable medium of claim 17 , wherein the iteratively modifying comprises, before performing the numerical simulation:

identifying any elements, generated from the current version of the three dimensional shape for the numerical simulation, that are partially but not entirely within the implicit surface; and

removing any of the identified elements that are not connected to any nodes of the current version of the three dimensional shape with Dirichlet boundary conditions, before performing the numerical simulation.

19. The non-transitory computer-readable medium of claim 12 , wherein the iteratively modifying comprises, before performing the numerical simulation:

identifying any elements, generated from the current version of the three dimensional shape for the numerical simulation, that are partially but not entirely within the implicit surface; and

setting densities of the identified elements equal to respective volume fractions of the identified elements, wherein a volume fraction of an identified element is a fractional amount of the identified element that falls within the implicit surface;

wherein performing the numerical simulation includes penalizing stiffness of the identified elements according to the densities.

20. The non-transitory computer-readable medium of claim 12 , wherein the one or more computer-controlled manufacturing systems comprise an additive manufacturing machine, and the operations comprise:

generating toolpath specifications for the additive manufacturing machine from the three dimensional model; and

manufacturing the physical structure corresponding to the object with the additive manufacturing machine using the toolpath specifications.