CAD geometry import for industrial 3D printing

The Dyndrite hybrid geometry core supports native 3D CAD geometry to provide a seamless workflow of spline and metadata inherent within your model. Maintain the integrity of native CAD-based spline and B-Rep data throughout the entire workflow while using metadata to automate your build preparation. CAD-based color metadata is maintained to establish specific print strategies across the part such as required surface finish and treatment of complex features. This metadata may also be used to automate the build prep process, including indicating type of supports, orientation,  label placement, etc.

Have multi-gigabyte 3D geometry?Not a problem. The Dyndrite Hybrid Geometry Core handles massive 3D data including STL files containing billions of facets.

CAD colors are maintained during import. Use this metadata to automate the build prep process, including indicating type of supports, orientation,  label placement, toolpaths, etc.

3D Volumetric Part Segmentation (without cutting corners*)

Dyndrite's Toolpathing API uses a GPU-based voxel engine to perform advanced 3D geometric queries on a part. This surpasses the limitations of traditional layer-by-layer boolean toolpathing methods.

3D fields are generated, thresholded, and booleaned to enable the assignment of different parameters within a single model using the API. The discrete zoning process allows you to develop a robust build strategy, resolving large and small features at the resolution of the machine. This enables high throughput in thicker sections, reducing the need for complex supports, and enabling new materials and special alloys. This ultimately allows you to expand the use of new materials and machines, further enabling new classes of part families.

• True 3D segmentation of parts using field-based queries
• Volumetric 3D assignment of parameters on each segment based on distance from upward or downward faces, or the nearest surface, while avoiding inefficient  2.5D up-skin/down-skin calculations
• Generate “feature-aware” machine tiles
• Use geometry to programmatically determine finely-graded process parameters
• Calculate upskin, downskin, orifice, fine vertical features
• Creation of an unlimited number of thresholds, using the API, to deliver accurate parameters to each condition in the build.

Example Output

Downskins, 5 distance thresholds pictured

Upskins, 5 distance thresholds pictured

Distance based inskin, 5 distance thresholds pictured

*  Machine oems tend to cut corners by conducting layer booleans up to 10 layers up and down in order to determine upskin and downskin. This is in contrast to dyndrite conducting a true volumetric analysis.

Color Channels (Greyscale or RGBA) and Distance Fields for Functional Grading

The Dyndrite Toolpathing API advances toolpathing out of simple monochromatic (on/off) instructions to full technicolor or grayscale. The generation of distance fields and evaluation in voxels space enables very fine control of all thresholds during Zoning and Segmentation for different processes. Color assignment to each threshold delivers comprehensive material and parameter control, faster than ever before. This combination of zoning, segmentation and color channels addresses builds that would fail or not be within tolerance using standard boolean-based toolpathing, and enables new materials and processes that require more advanced strategies.

• Use voxel metadata to drive sophisticated parameters for the light engine in a photopolymer process.
• Use voxel metadata to drive sophisticated parameters for the print head in a binder/material jetting process (picoliters of fluid/material, fluid/material type, etc.)
• Use the API for voxel level control for functionally-graded materials
• 1,2,4,8 bit grayscale or 8 bit RGBA

Above 3 images left to right:

• Traditional monochrome image used to represent slice data
• Grayscale representation of slice data where the outer contour, offset, lattice, and voids are represented with different grey values
• Zoned and thresholded part where color is used to define distance values, and normal direction of the nearest surface

Anisotropic Compensation

Additive toolpath adjustments compensate for known anisotropic material properties or process physics.

• Accounts for direction of print, direction of recoating, and direction of tool travel
• Binder jet and LCD/DLP - ink bleed, light scattering, thermal expansion, and suction
• Six scalar values - three for scaling in X, Y, and Z, and three for offsetting

GPU-based performance for 3D industrial printing

The data in additive manufacturing is exploding. Yet, controlling and being able to manipulate this data is required to produce exact, repeatable parts.  Dyndrite effiencently manages data compute taking advantage of multi-threaded CPUs and scalable GPUs to enable users to handle even the largest datasets.

• 1000s of parts per build with fully nested build volumes
• 4k, 8k, 600dpi, 1200dpi, 1800dpi rasterizations
• 500 - 1000mm^3 build volumes
• 3D nesting, supports, labels, and instancing