# Patent

## Title
Made-to-order direct digital manufacturing enterprise

## Abstract

Methods and systems for designing and producing a three-dimensional object selection of a base three-dimensional object from a customer device. A base three-dimensional model corresponding to the object is displayed on the customer device, and one or more custom modifications are received. A modified three-dimensional model corresponding to the modified object is prepared and displayed. Once confirmation to produce the modified object is received, data corresponding to the modified three-dimensional model is transmitted to a manufacturing device for production of the object, using the data to do so, such that the object corresponds directly to the modified three-dimensional model.

## Background
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority to the co-pending U.S. patent application having the Ser. No. 11/750,499, filed May 18, 2007, the entirety of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to the design, sale and manufacture of made-to-order or mass-customized products. More specifically to a computer-based method and system for customer-driven design, sale and manufacturing of unique or custom-made product(s) exclusively through a highly efficient sales & manufacturing system which advantageously combines key elements of computer aided design methodologies, the interne and Additive Fabrication methodologies to personalize or customize said products.
BACKGROUND OF THE INVENTION
The customization of durable goods products is a desirable characteristic that many retail markets would enjoy being able to broadly utilize and many consumers would enjoy broadening their product selection and bringing what they buy closer to what they want. Unfortunately sales, distribution and manufacturing systems designed to deliver mass-manufactured goods to consumers and or job-shops that do custom manufacturing are not positioned to effectively deliver mass-customization, generally placing custom-designed products out of the reach of consumers. Additionally, the machines, methods and labor are ineffective at delivering customization cost-effectively. An example is the manufacture of class rings or other jewelry. The diversity of these products is defined by the selection of molds and tooling used to inject wax which is used to cast the final product. A manufacturer cannot provide an infinite product selection or face the challenge of also producing and storing an infinite number of molds and tooling parts.
The customization characteristics desired by individuals are diverse and therefore, the method is applicable to a wide array of products. For example; a customer may desire a custom-designed broach or ring that contains a 3D representation of a family crest or insignia. To obtain this custom product requires specialized training including 3D CAD modeling and design experience or at the very least CNC programming experience. Other customizable products might include custom valve covers for a hotrod. Designing these products and having them manufactured by CNC machining would be expensive and, the equipment necessary is not normally available to the general public nor are the operating procedures of the equipment. Therefore; customization options for consumers are often limited and access to customization of products is difficult. The result is that individual needs and or desires are not always met and customers therefore settle for less than what they wanted or desired.
Computer-based networks, access systems, websites, databases, processing speeds and 3D geometry manipulation have reached a sufficient level of performance to provide consumers with the ability to drive changes to products themselves in many aspects. Consumer capabilities to understand such systems have also reached a level sufficient for consumers to realistically be involved in at least some aspects of a design process, for example those that do not cause risk to a customer or liability to a manufacturer as defined by constraints preventing a customer from violating the constraints during design for personalization or customization.
Computer-based geospatial/3D design & design implementation systems are based on point-of-use deployment models. Such systems are also intended for use by someone skilled in the art of CAD/CAM and design methodologies. This effectively means that manipulation of the geospatial/3D geometries commonly called CAD models requires advanced knowledge and significant time to develop. When properties such as structural integrity or thermal properties are involved, even basic design skills for 3D move out of the realm of consumers with basic skills in this area, often to an advanced engineer-level which is beyond the comprehension of the general public. CAD systems are also precise and unforgiving in many aspects of their use. Some examples of 3D design tools include Autodesk Inventor, Solidworks, Unigraphics, CATIA, Mechanical Desktop, MAYA, Rhino 3D, 3D Studio Max and more.
Computer-based 3D design and design implementation systems are required to produce a product by additive fabrication methods. Such systems are costly and must be purchased by a user and added to the user's computer. The user must also learn how to use the system, the engineering behind designing a product and finally, locate a facility to produce the product. Also, designing a product from scratch is time consuming, even for someone skilled in the art of CAD/CAM design, engineering and manufacturing.
Rapid Prototyping and Additive Freeform Fabrication are used interchangeably to describe technologies that have been developed to create or “manifest” 3D objects representative of computer-based geospatial/3D geometry through the process of depositing materials in an additive or layered process, resulting in a net or near-net shaped product conforming to the dimensions of the 3D computer-based geometry upon which such an object is based without tooling or molds or much of the labor required in traditional subtractive methods of manufacture. At present there are approximately 25 additive fabrication processes covered by various patents. Each technology has inherent limitations and benefits including the feature resolution, materials that the technology can use, speed, surface finish and a plethora of other parameters by which a part can be measured however; the deployment model of such technology is, for the most part, considered for prototyping and not for direct digital manufacturing. For example; a wax polymer is ideal for the manufacture, by lost wax investment casting, of custom jewelry. Solid-Scape additive fabrication technology is ideally suited for the manufacture of jewelry. Solid-Scape hardware is capable of printing or manifesting, at high resolution in a relatively small build envelope. Other technologies, such as Selective Laser Sintering from EQS are suited for the manufacture of larger components made from nylon materials or a limited selection of metals however the surface finish of the SLS process is considered rough when compared to other processes.
Current deployment methodologies in use for both CAD/CAM systems and additive fabrication technologies limit the widespread use of the aforementioned technologies. For example, manufacturing more than a small lot of products on any given machine in a reasonable timeframe is thwarted by throughput. However, if machines in one location were linked to machines in multiple distributed locations, the effective capacity would be greatly increased. The net result of these differences is that all of the various additive fabrication processes may be required to provide the net result of a finished product consistent with expectations for a particular product. Since it is prohibitive for any one facility to own every machine of every type from every manufacturer, it is advantageous to link many facilities together, further realizing the full potential of additive fabrications.
Computer-based implementations of Product Lifecycle Management (PLM), Product Data Management (PDM), Master Production Scheduling, part routing and part nesting systems are capable of intelligent and automated actions to manage decisions for operations in a production capacity and planning system and can include other intelligent decision-making abilities such as procurement and inventory management but they are designed to move “real” products, not virtual products through the system.
It is therefore beneficial to effectively combine additive fabrication, Computer Aided Design methods, capacity planning and the Internet with automated PDM/PLM production scheduling and routing systems in a manner that enable deployment of additive fabrication methods and technologies as an Enterprise Resource Planning (ERP) production system. As such, embodiments of the present invention advantageously create a disruptively competitive and efficient system for the design, sale and manufacture of individualized or customized products by synergistically combining facets of many technologies into a more productive method and tool.
SUMMARY OF THE INVENTION
In light of the preceding background, embodiments of the present invention provide methods and systems for user/customer selection, design, sale and manufacture of customized/personalized products through a streamlined and/or automated or semi-automated process combining computers, the interne, 3D modeling (also called CAD modeling), a customization interface including an interactive controls suite connected to the 3D modeling system for the purpose of allowing a user/customer to personalize or customize a product represented by a 3D geometry or multiple 3D geometries, whereby the user/customer is connected to the Cad modeling system through a website or web portal along with a 3D viewer connected to the 3D CAD geometry manipulation system for the purpose of providing design feedback and pre-purchase visualization to said user/customer accessing the system through said website or web portal, whereby said product is manifested in an automated or semi-automated fashion via additive fabrication methodologies. Embodiments of the present invention improve operational performance in a design, sale and manufacturing system to design, manufacture and sell a wide variety of products which can be adequately defined by one or more computer-based design and design implementation methods to 3D geometry manipulation where said geometry can be properly manifested by any additive fabrication technique.
According to one embodiment of the present invention, the method is carried out by a computer-based system which includes at a minimum; a computer, a software-based geospatial/3D modeling engine (a CAD engine), input/output controls to the 3D modeling engine, a 3D viewer engine, a database or file system and a production routing and scheduling system interconnected with additive fabrication hardware.
Embodiments of the invention are designed to interface a customer directly with the digital representation of their intended physical manifestation, thereafter referred to as a product. In essence, the customer is peering through an interne “portal” at the customer's unique product and can interact with it during the design process. Any changes made by the user of the system that occur to the product become unique facets of the particular product the user/customer is building or creating for purchase. Embodiments of the system are capable of interfacing with a plurality of customers simultaneously and are designed to do so.
Another embodiment of the invention can automate most and in some cases all, of the post-sale production operation, thereby removing most, if not all, of the human factor requirements from the system and thereby removing or minimizing the number of people involved within production environment, further optimizing the manufacturing process, maximizing productivity and minimizing labor needs.
Advantageously, embodiments of the system are conceived to be capable of assembling and modifying 3D components of a customer's unique product in increments measured in milliseconds while the product exists as a mathematically-derived 3D model or models. This is many orders of magnitude faster than any other known production system available today.
Embodiments of the method and system can utilize additive fabrication for manifestation of a unique product or component(s) of a product, thereby making the systems' inventory highly flexible. Embodiments of the system are designed to use the full gamut of available Additive Freeform Fabrication technologies collectively making possible production of products with diverse materials. Since embodiments methods and systems are developed around the concept of 3D geometry and CAD modeling, the methods described herein can include future Additive Freeform Fabrication technologies as the intended output technique inasmuch as the additive fabrication technique relies on 3D data as the basis for output through the additive methodology.
Furthermore, embodiments of the present system provide a completely flexible and scalable production operation. Deployment models may include an “in-house” model where all additive fabrication hardware resides in a single facility or at multiple facilities including diverse and/or divergent locations. Capacity within a locally deployed system can be expanded by purchasing additional Additive Freeform Fabrication hardware and adding it to the system or by taking advantage of distributed networking, the interne and available additive fabrication hardware available at other facilities. These facilities may include bureaus or other manufacturers using one or more embodiments of the present system(s).
Furthermore, embodiments of the present invention may make use of multiple types of additive fabrication hardware simultaneously or concurrently to manifest a plurality of components of an assembly for a product that is, by design or by desire, necessary to be made of different materials and assembled from the various components. The system in this situation would be responsible for routing components that must be manifested out of differing materials to several or many local or remote locations for fabrication via additive fabrication processes that support fabrication of the desired or required material substance. Examples of this material might include metals of varying natures, plastics or polymers of varying nature, waxes or even composites or slurries. Such varying needs can require use of the entire gamut of Additive Freeform Fabrication hardware.
In another embodiment, the method and system can be accessed by a user/customer via one or more communication methods whereby the user/customer accesses the system over the communication network, the method providing the user a plurality of product selections to said user/customer back through the communication method, receiving from said user/customer via the communication method a selection of a product or products, and providing said user a customization/personalization interface, the customization/personalization interface providing at least one personalization/customization tool or option to said user/customer to create an individually customized product and whereby said customization/personalization option does not violate any parameter prevention its manifestation through Additive Fabrication methodologies.
In another embodiment, a three-dimensional model and/or a corresponding product produced (e.g., via additive fabrication) using the three-dimensional model can be provided with a custom “digital traveler” feature, which can include any manner of physical feature. This digital traveler information can thereby follow a three-dimensional model throughout the process, enabling tracking thereof, and can eventually be converted from a model to a physical portion and/or feature of a resulting object (e.g., a protruding tab, placard, appendage, or similar geometry), thereby enabling an object to be readily identified.
Wherein the summary of the invention provided, including certain aspects, advantages and novelty of the invention have been described herein. It is thoroughly understood to one skilled in the art, that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the invention. Thus; the invention may potentially be carried out in one or more manners that optimize one or more advantages as described herein without achieving other advantages as descried herein.
These and other embodiments of the present invention shall become apparent to anyone skilled in the art whom review the detailed description of the embodiments herein including but not limited to figures, features, or other descriptions disclosed.
DESCRIPTION OF RELATED ART
Software applications for CAD modeling exemplified by those from Solidworks Corporation and Autodesk, Inc., include tools designed to provide for mechanical deformation and or mechanical assembly of a plurality of individual 3D parts to create an “assembly” where each discrete component is represented in the assembly as a 3D model and therefore the assembly is also a 3D model. The purpose of said software is mechanical design and design validation. Said software was intended to be utilized for the purpose of design and design validation by a designer or more specifically a design engineer who is someone that understands the intricacies of mechanical fit and function.
Manipulating a single file that is part of an assembly in Solidworks, Inventor and other mechanical design software can impact an assembly of parts and therefore the assembly will also reflect the modifications including feedback on collisions of parts and an inability for the combination to exist physically. Solidworks U.S. Pat. No. 6,308,144 encompasses some of the concepts of moving and or repositioning objects in an electronic manner representative of mechanical assembly of physical products. Autodesk also has a similar assembly method within their software that electronically “bonds” 3D objects in the computer in a manner similar to Solidworks. Such is the nature of mechanical design software, to validate and help drive accurate and meaningful reduction in design cycle times by allowing an engineer to design the product virtually. Without this assembly methodology, the design and analysis would not be possible.
All 3D design and modeling software is built on a commercially available 3D CAD engine. The most popular 3D CAD engine today is made by Parasolid and embodied in U.S. Pat. No. 6,489,957; “Three dimensional geometric modeling system with multiple concurrent geometric engines”. Other 3D CAD engines exist such as an older system called ASIS. Other CAD systems exist. Most products including Parasolid are available commercially for purchase and licensing, just as they are to Solidworks.
3D viewer technology exists in a plethora of formats including the most popular format, Open GL. 3D viewers exist and render 3D geometries represented by mathematics on a computer screen, often seen at CAD workstations, in video games or other graphics applications for the purpose of providing the design engineer or artist the ability to see feedback of a 3D model on their design choices iteratively. 3D rendering and viewer engines are also used on the interne to provide, interactive catalogues of 3D models that a user can download and then use in their own designs or modify mechanically via software including Solidworks. These systems are used to provide only CAD models that are used by design engineers.
Solidworks 3D parts Stream is an interactive catalogue. It is a supplemental application of the Solidworks product which utilizes API-calls to the Solidworks software application to cause the software to manipulate geometry and deliver the results through a visualization system of products through a networked or internet-based system. The intended use of this system is to create 3D models that can then be downloaded and embedded in 3D designs during product design and validation processes as a time-saving tool. Furthermore, the 3D parts Stream product relies on the Solidworks software which in and of itself has limited or rigid functionality such as a very rudimentary ability to manipulate textual information. Furthermore; the output of the Solidworks application terminates as a 3D model which can then be embedded into a product development design. The product and process is intended as a time-saving apparatus for product design and validation. This is analogous to providing a way so that the design engineer does not have to re-draw a washer or castor or screw or some other part every time they need such a part for a new product they are designing. Solidworks brochure for the product states; “A 3D-powered catalog that allows components to be quickly downloaded and “designed in” offers greater convenience for the product designer.” Thus is the scope of the 3D parts Stream intended use.
Rapid Prototyping or Additive Freeform Fabrication hardware of many types exist and are used today to provide prototype and limited-production output of 3D models to be used in visualization and low-cost, high-accuracy sample production during the design process, hence the name Rapid Prototyping. To date, some companies are also utilizing Rapid Prototyping or Additive Freeform Fabrication hardware for limited production of products intended for functional end use directly from, or with minimal post processing, directly from the product manifestation via Additive Freeform Fabrication.
Available CAD systems for purchase today are either mechanical design in nature or artistic in nature. Both systems have their merits and both systems have their drawbacks. Mechanical systems lack many of the aesthetic or Industrial Design elements of product design and manipulation software. Industrial Design or artistic software lacks the exacting controls necessary to define a mechanical system. Neither system is developed nor intended to be accessed and driven by a typical consumer wherein the consumer is one not skilled in the art of 3D design. The limitations of mechanical design systems extend to text information, fonts, complex or ergonomic or aesthetically please design elements.
Furthermore the systems and methods described as prior art above are not known to be combined in any manner or similar nature for the purpose or spirit of use as a complete manufacturing enterprise system in any resemblance of the method described herein, a Made-To-Order Digital Manufacturing Enterprise System which; combines one or more computer based design or design implementation methods (CAD/CAM) systems, the internet, websites, or web portals, e-commerce systems, Product Data management, product lifecycle management, master production scheduling, routing & nesting systems into a consolidated system designed exclusively for customer-driven design or design modification to geospatial/3D files which represent the final product.
U.S. Pat. No. 7,216,092 Weber, Et Al embodies a patent related to mass-customization of products in a vague similarity as the patent embodied herein however; the primary differentiator is that U.S. Pat. No. 7,216,092 is obviously, to one skilled in the art, intended for 2-dimensional printed merchandise and not geospatial/3D products. Furthermore, U.S. Pat. No. 7,216,092 embodies at least some techniques and concepts already in practice, for example, www.vistaprint.com has been using a website-based user/customer driven design system for approximately 7 years in customer-driven design and manufacture of custom printed business cards and stationary including; a database for storing and retrieving designs created by a customer through the system. Furthermore; U.S. Pat. No. 7,216,092 discloses a purpose for design by an individual and not a collaborative group.
There is no known prior art combining the methods and systems described herein including; geospatial/3D CAD/CAM data, presented to a user/customer, whereby the actual geospatial/3D geometry presented to the customer is used for purchase intent, including modification or customization for the purpose of modifying to suit individual tastes or preferences is done so through the website or web portal with the intent is purchase by the user who is considered to also be a user/customer and the product is produced in an automated or semi-automated production method including scheduling, routing and automation or semi-automatic manifestation of said part or assembly via Additive Freeform Fabrication where the output of the Additive Fabrication process or processes is considered the final product or where parts together, produced by Additive Fabrication methods collectively comprise a product for purchase through such a system.
Finally, there is no know practiced application of said method or system registered or in use through the internet by consumers which shows prior art as described herein.



BRIEF DESCRIPTION OF THE DRAWINGS
Having thus described the invention in general terms, reference will now be made to the accompanying drawings by example where the drawings are intended to illustrate and not limit the invention wherein;
FIG. 1 depicts the creation of a geospatial/3D CAD model representing a product is established within a CAD system.
FIG. 2 depicts a website or web portal as part of the method and system for user/customer-driven selection, design, purchase and manufacture.
FIG. 3 depicts the computer-based system carrying out a preferred embodiment of the present method.
FIG. 4 depicts an additive fabrication machine or 3D printer.
FIG. 5 is a flow diagram depicting an embodiment of the present method.
FIG. 5A depicts an embodiment of a method for using a web portal or website system.
FIG. 5B depicts an embodiment of a method for using the interface providing user/customers the ability to interact with and drive iterative design changes to their product into a 3D engine.
FIG. 5C depicts an embodiment of a method for using a 3D viewer or rendering engine.
FIG. 5D depicts an embodiment of a method for using database(s) and/or file system(s) responsible for storing product models, product data, temporary files, metadata or other data usable to carry out embodiments of the method of the present invention.
FIG. 5E depicts an embodiment of a method for using one or more 3D modeling or CAD engines that are responsible for manipulating the 3D data according to inputs by a customer through the relational control system depicted in FIG. 5B and connected to the customer via the 3D viewer system depicted in FIG. 5C and ultimately viewed through the Web Portal depicted in FIG. 5A.
FIG. 5F depicts an embodiment of a method for using a PDM/PLM/master production scheduling system responsible for managing an automated or semi-automated production process.
FIG. 5G illustrates an embodiment of a method for using a product stacking system.
FIG. 5H illustrates an embodiment of a method for using a part nesting system.
FIG. 5I illustrates an embodiment of a method for the addition of identification markings on a product represented by 3D geometry.
FIG. 5J illustrates an embodiment of a method for using payment processing system.
FIG. 5K illustrates an embodiment of a method for using an intelligent material selection system.
FIG. 5L illustrates an embodiment of a method for using a distributed manufacturing system.
FIG. 5M illustrates an embodiment of a method for using a quality rating system for a distributed manufacturing system.
FIG. 6 is a flowchart depicting the use of the preferred embodiment of the present invention whereby the system in this example depicts the manufacture, by manifestation, of a wax pattern for a custom class ring, designed through the present invention by a user/customer.
FIG. 7 illustrates a lot or “tray” of digitally routed and nested individual orders ready to be manifested via Additive Fabrication methodology including a sprue containing information to identify aspects of each unique product.
FIG. 8 illustrates process flow of the method in a preferred embodiment, representing the scalability of the system by adding additional additive fabrication machines.
FIG. 9 depicts an embodiment of a website or web portal for using a local or remote CAD system containing tools for defining product interactions, and limits on configuration and user/customer inaction, hereafter referred to as constraints.
FIG. 10 depicts a diagrammatic view of an embodiment of a database or file system containing a plurality of individual products.
FIG. 11 depicts a product core with a suppressed feature, shown as a sprue.
FIG. 12 depicts a product core having modification regions, usable to add 3D art and/or other mating parts to the product by the 3D CAD engine.
FIG. 13 depicts a 3D model for representative purposes, showing a stone for addition to a top or bezel of a customized ring.
FIG. 14 depicts various modification regions or “panels” of a product showing two-dimensional and three-dimensional text added to the regions by a 3D CAD engine.
FIG. 15 depicts a 3D model for representative purposes, showing a top or bezel of a customized ring.
FIG. 16 depicts a stone, such as that shown in FIG. 13 mated with a bezel, such as that shown in FIG. 15.
FIGS. 17 and 19 depict network diagrams of embodiments of the present system.
FIG. 18 illustrates a website containing an example of a user interface allowing the design of a custom motorcycle gas tank being embossed, by 3D displacement mapping, with flames.



DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS
Embodiments of the present invention will now be described in detail with reference to the associated drawings, in which preferred embodiments are shown. This invention may, however, be embodied in varying forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be complete and thorough, and will fully convey the spirit of the invention.
FIG. 1 represents a geospatial/3D geometry system, commonly referred to by someone skilled in the art as a computer aided design or geospatial design and configuration system or CAD system which for the intent of disclosure, is intended to be defined as a means to design a product which may be made available for customization/personalization within the present invention.
In one embodiment, the system deploying the method of the present invention, shall allow for the input of any geospatial/3D geometry design produced in a plurality of design software tools including but is not limited to Solidworks, Inventor, Rhino, Strata-Studio Pro, Maya, CATIA, PRO-E, Alias Wave Front, Alias Sketch, Lightwave 3D, DesignCAD, Enovia Amapi, Carrera 4, Hexagon, Shade 3D, Poser 6, Axel Core, Recon 3D, Anatomica 3D, Adobe Dimensions, DelCAM, Form-Z, Mechanical Desktop, Pilot 3D, Solidthinking, Unigraphics, TouchCAD, etc.
The present invention therefore can accept and utilize geospatial/3D geometry created by of the aforementioned geospatial/3D graphics application because 3D graphics applications export 3D models for cross compatibility purposes into many common 3D file formats. FIG. 1 Further represents a CAD designer or user/customer creating the desired features, including the interaction mechanisms which the consumer will be able to manipulate for the particular product(s).
FIG. 2 illustrates a website providing access to the system deploying the present invention; the example illustration reflects a website making available for sale custom jewelry. This representative website or web portal provides the link between a plurality of customers, the database(s) of product(s) available for customization, the 3D viewer system, the geospatial/3D engine system, the database system and the production system for manufacturing custom jewelry products.
It should become obvious by now that the limitations on what can be manufactured using this method and system as described herein are defined by the materials available to an additive fabrication machine and an ability to adequately define a 3D object to allow for its printing via additive fabrication means.
FIG. 3 represents the computer-based system which deploys the method of the present invention. The computer-based system runs on a computer server or computer servers utilizing an operating system. The software/hardware system is programmed to store and retrieve 3D data from a database, present it to a user/customer via the website or web portal, along with a design interface and a 3D view of the product. Said software system is also responsible for the sorting, scheduling and routing of a plurality of orders processed through the system by a plurality of users/customers. Furthermore the system is responsible for sorting, routing, nesting and scheduling said product(s) for production only after payment is received and customer approval of the 3D product visualized through the web site or web portal. The system provides for iterative design feedback prior to approval and production.
It should be obvious to anyone skilled in the art that the system could be deployed in manners which negate the need for pre-payment prior to production. For example: in delivering an order of a product to a business client who purchases on a purchase order or where no payment is required such as battlefield forward manufacturing or where the order is a repeat order
FIG. 4 illustrates an exemplary Additive Freeform Fabrication device. This device or a similar device is usable for the manifestation of a customer's unique product. The illustration is therefore intended to be illustrative of a 3D printer and not inclusive of all usable 3D printing equipment.
FIG. 5 is a process flow diagram illustrating one preferred embodiment of the method of the present invention. The diagram represents the interconnectivity of the various components and processes which together comprise a system and method capable of delivering an overall Made-To-Order Digital Manufacturing Enterprise System within the scope of the present disclosure.
FIG. 5A illustrates an embodiment of a method for using a website or web portal providing connectivity between a user/customer and the system deploying the method of the present invention, wherein the website or web portal provides a means for the user/customer to access the system and for the system to provide feedback to the user/customer, creating an interactive system.
As used herein, the terms “communication network” and “Internet” refer to any networking method that provides a user/customer access to the system described herein from a remote geographical location. The communication network providing two-way data communication between the user/customer accessing a website or web portal located on the World Wide Web which interfaces with said system.
As commonly understood by someone skilled in the art of the internet or e-commerce, a website or web portal refers to one or more web pages that collectively comprise a website, the website being accessible over a communication network from remote geographical locations and transferring data including but not limited to HTML, Java, or any other computer-based data, to and from a user and or user computer from one or more remote computer systems. Said website containing, for example; images, HTML, CGI, JAVA, FLASH, AXAX, ACTIVE X CONTROLS, VIDEO and other computer code to present a useful tool to a user/customer visiting the website. Said data representing content intended for a user/customer to view, interpret, and utilize for a purpose as understood commonly by anyone skilled in accessing and using the internet or World Wide Web.
In one embodiment, the website provides by the current invention includes multiple web pages, collectively comprising a website, with a home page whose meaning is clear to anyone skilled in the art of the internet and e-commerce. The website is accessible by a web browser in response to a user/customer http request resulting in the presentation of the website through its URL by which all web pages are categorized, organized and located on the internet
A user/customer as described herein can include any person who accesses a website on the internet for the purpose of gathering information, learning, experiencing or purchasing by e-commerce. This description is extended to users who may be involved in collaborative design efforts. The terms described here are provided to represent, rather than limit, the terms describing a user/customer.
The website or web portal depicted in FIG. 5A is designed to provide users desiring to customize for the intent of purchase, personalized or customized products including any product which may be adequately represented by 3D geometry so as to allow 3D printing via Additive Fabrication methods. The website further contains one or methods to browse and or search for products contained in said system to customize or personalize and purchase. Said website or web portal further provides the means by which the user may access the system that provides the user an interface through which they may personalize or customize aspects of a product including but not limited to; color, shape, texture, function, thermal, mechanical, electrical properties, location of appendages or other 3D geometries affixed to a core product, including text, fonts, scale or other parameters of text which may be manipulated whereby said Text becomes manifested as 3D geometry or 2D geometry on the surface of a 3D geometry wherein the ability to see such 2D geometry is meant to include any means which differentiates it from the surrounding material to make it legible including but limited to color or texture.
Product manipulation and design parameters are intended to mean any modification which is feasible via geospatial/3D design modifications to a 3D object which does not violate its fit, form or function. Furthermore; product manipulation and modifications refer to any design detail or modification that augment or enhance the original product to meet an individual or personal need or desire.
Individual or personal enhancements may also include user/customer original design modifications by someone skilled in the art of 3D design and design implementation so as to create undefined enhancements to a product or an entirely new product design having the same purpose or an entirely new purpose.
The website or web portal of FIG. 5A includes the ability to include rendering geospatial/3D models to a user/customer allowing the customer to see the closest approximation of the actual physical product that is superior to all other visualization methods because the 3D entity they visualize is in fact the digital representation of their actual product.
A computer or computers deploying the method and system of the invention may include any computer system as commonly understood by anyone familiar with the common definition of a computer including computer systems with processor(s), temporary & permanent storage mediums, input/output controls, network connectivity and an operating system. Furthermore, said computer(s) contain programming code in any known explicit or implicit method whereby the code described is responsible for, solely, or in combination with hardware, causing the computer(s) to carry out operations to provide the method of the present invention described herein. Said software and or hardware clearly understood to carry out the purpose as defined to anyone skilled in the art of computers and networking.
A distinction is made between a computer or computers carrying out systems and methods usable within the scope of the present invention and a user/customer computer, whereby a user/customer accesses the computer or computers carrying out, by way of computer software and hardware, the methods of the present invention. A user/customer computer can include a PC, Smartphone, home computer, desktop computer, notebook computer, tablet PC or combination thereof.
To further explain the method and system, detailed description is provided for the remaining diagrams and drawings:
FIG. 5B illustrates an embodiment of a method for using a local or remote software or software and hardware-based system providing the set of relational controls that provide a user/customer with interactivity, e.g. through the website or web portal to personalize or customize a product and the 3D CAD system.
FIG. 5C represents a method for using the geospaital/3D viewer system that is responsible for rendering 3D geometry to a user/customer or plurality of users/customers, through the web portal, and hereafter referred to as a 3D viewer. The 3D viewer provides a user/customer, using the system through a website or web portal, with a means to visualize their product and the resulting changes in 3D.
FIG. 5D illustrates an embodiment of a method for using a set of databases and/or file systems which can be used to store and retrieve data during the operation of the computer system. FIG. 5D further represents one embodiment of process flow within the system.
FIG. 5E represents one or more approaches to geospatial/3D design and design implementation responsible for the accurate assembly, deformation or otherwise manipulation of the 3D mathematically-derived geospatial/3D models. The method may utilize but is not limited to the Parasolid or ACIS kernel and may also be a custom-designed 3D kernel system that better meets the needs of the invention if such a pre-made system proves to provide limitations on the systems functionality or scope. This geospatial/3D system accepts input to drive the accurate assembly, deformation or otherwise manipulation of 3D files at the instruction or input of a user/customer such through the design interface accessed through the website or web portal. Furthermore the 3D kernel system may, in one embodiment also be responsible for any post-processing necessary to put the 3D files in the necessary file format required for production according to claim 25.
FIG. 5F illustrates an embodiment of a method for using the portion of the system responsible for Product Data management, Product Life style management, and/or master production scheduling, whereby products represented by 3D model(s) are, by the system, automatically sorted, scheduled and routed as a plurality of individualized or custom-designed products, to a location where the resultant 3D geometry can be manifested via additive fabrication through the system and method described herein.
The system represented in FIG. 5F also provides for automatically sorting, scheduling and routing the plurality of individualized or custom-designed products to a locally available or remotely located Additive Fabrication machine, machines or bureaus.
According to presently understood operations of a manufacturing product lifecycle, product data management, master production scheduling, part routing system described in FIG. 5F shall, in one embodiment, be further capable of conducting intelligent or semi-intelligent decisions on how to best organize individual orders for timely production and delivery to a customer or customers including but not limited to the physical location of the bureau and or the customer.
Furthermore; according to commonly understood terminology used in manufacturing, the system illustrated in FIG. 5F shall be considered to include an automated production scheduling system responsible for automatic or semi-automatic routing and production queuing of the geospatial/3D models hereafter called products, being moved through the system.
FIG. 5G illustrates, according to widely accepted and understood meanings of the word nesting as used in manufacturing, a method or methods to automatically add 3D product(s)s to a single file representing a “batch build” on available Additive Fabrication machine connected to said system.
FIG. 5H illustrates an embodiment of a method for partial nesting that can include 2d and 3D nesting of products in an intelligent or semi-intelligent method, whereby decisions are made by the system to optimize the utilization of the build envelope of a 3D printing additive fabrication machine.
FIG. 5I illustrates an embodiment of a method for the addition of identification markings on a product represented by 3D geometry which are added as a 3D appendage, placard, tab, or directly to a surface of a part or product to convey information, which can be carried digitally, about said part or product into human or machine readable form including information about the part, the date of manufacture, customer information or other pertinent information. The method can be carried out by one or more approaches to 3D geometry manipulation metholodigies, the location and content being defined by either a user or customer or automatically by the system, and the geometry being manifested, along with the geometry representing a user/customer product via one or more additive fabrication methodologies at the time of production of the user/customer product at one or more locations.
FIG. 5J illustrates a method for using a payment processing system as part of an e-commerce system. The payment system is responsible for approving orders, based on payments prior to producing products through the system.
FIG. 5K illustrates a method for using a system to intelligently determine what material and therefore what additive fabrication machine is best suited to produce the particular part or product.
FIG. 5L illustrates one preferred embodiment of a method for facilitating the distributed manufacturing of products processed through the system, including remote locations where additive fabrication equipment resides, such as bureaus. The system may include intelligence to help the system determine how best to distribute the products for manufacturing including, for example, the relative distance from the bureau to the customer's address.
FIG. 5M illustrates one preferred embodiment of a method for facilitating the decision to use a distributed manufacturing location, such as a bureau, by analyzing parameters of the bureaus which may include a subjective rating system to discern the reputation of the facility for producing quality work and/or producing quality work in a timely manner. The system may include many parameters by which a facility, connected to the system, is chosen or not chosen to produce a product for a user/customer through the system.
FIG. 5A through 5M represent collectively, a flowchart depicting the spirit of the present invention and the preferred embodiment thereof such that the system carries out the automated product and processing of customer-designed, customized or personalized products manufactured by additive fabrication.
FIG. 6 represents a flowchart depicting a use scenario for automated production as described above in the manufacture of custom jewelry.
FIG. 7 depicts a nested tray of assorted unique custom products, complete with identification markings affixed to the sprue of the product by the system in an automated fashion. The nested tray depicted is thereby ready for production either locally or remotely. In this case, the products are custom jewelry.
FIG. 8 illustrates one embodiment of the present invention as a commercial product entitled “Digital Factory”. The system is a scalable, self contained product integrating all of the various components of the system described, for the purpose of developing, producing and making for sale products to users/customers through the automation of the system, thereby providing a system with productivity advantage, pre-purchase visualization advantage, operational advantage, inventory advantage, order accuracy advantage, and labor productivity advantage
FIG. 9 depicts an example web portal for accessing the system. The depicted web portal is usable for the custom design of a jewelry product, whereby the customer drives the selection and assembly of the product with chosen options and includes the ability to use the design interface presented to the user/customer to add pictures which are converted to 3D geometry through methods including but not limited to displacement mapping. The interface can also enable the customer to see the resultant of the customization/personalization.
FIG. 10 depicts a database and/or file system containing a plurality of individual products, each depicting a different set of 3D geometry or art. In this representation, the database enables selection of art panels that each are either rigid in design or contain editable parameters such as text or art and can themselves be interchangeable with each other. The products in the database can include any product which is capable of being adequately defined by 3D modeling in which an additive fabrication machine may print said geometry.
FIG. 11 represents a product core with a suppressed feature, in this case a sprue on a class ring. The sprue can be a necessary part of a casting operation. However, the appendage in this case is not an object that the consumer would wish to visualize during the design process. Therefore, the feature may be suppressed so as not to be visible to the user/customer as defined by the entity who devised said product for sale through said system.
FIG. 12 depicts a product core to which art can be attached by the CAD system in response to a customer's request, and to which a “top” or “bezel” can be mated, in this case, to form a class ring. Attaching multiple parts to define a product is within the scope of definable parameters they system may allow users/customers to modify on a product or products.
FIG. 13 depicts a 3D model for representative purposes, showing a stone for addition to a top or bezel of a customized ring. There may be many stones and bezels to choose from in designing a unique product. Each stone or bezel may contain editable features including text, art or other geometry. Editing sub-level fields of each object is applicable to a plethora of products to define their unique characteristics for an individualized or customized order.
FIG. 14 depicts various modification regions or “panels” of a product showing two-dimensional and three-dimensional text added to the regions by a 3D CAD engine.
FIG. 15 depicts a 3D model for representative purposes showing a top or bezel for mating with a stone of a customized ring. While the bezel will often contain editable features, the stone is a part that is often a suppressed feature in the manufacturing operation of additive fabrication since stones may be real or synthetic in nature. However, the stone in this example is an object that would be used for representative visualization of a finalized class ring containing the stone and bezel.
FIG. 16 depicts a stone, such as that shown in FIG. 13 mated with a bezel, such as that shown in FIG. 15. This geometry would be used for visualization by a consumer using the web portal so that the consumer may accurately portray the 3D representation of the final product. Such a feature would be suppressed if necessary, such as in the case of a class ring, by removing its geometry from the overall geometry before the product is manifested via Additive Freeform Fabrication.
FIGS. 17 and 19 illustrate network diagrams of embodiments of the present invention, wherein the illustrations depicts how a user, using a computer of varying forms including a PC, a notebook, or a smart phone or other device can connect to the system of the present invention through a router, a wireless access point, a modem or a wireless network such as a CDMA network. The illustrations of various connectivity methods are intended to be illustrative instead of restrictive in nature. The connectivity methods described thus far allow a plurality of users/customers to access the system through a communication network and connect to a web server. The web server is shown connected to a plurality of servers including a database server, a file server, an e-commerce server, a content management server, a directory server, an FTP server, a print server, and a proxy server with or without a firewall. Said servers are shown collectively connected to a local array of 3D printers. The system is also, in the embodiment presented, connected, through a network connection, to a remote array of servers, wherein each remote location contains 3D additive fabrication hardware. The remote additive fabrication hardware may be contained in a bureau or factory or an individual's home including the home of someone accessing the system such that the printed product is printed in the same geographical location as the user/customer. The various servers are presented in this format to illustrate the system deploying the method and are not intended to be inclusive. Furthermore, the servers presented may be virtual or contained in a single server or servers located in the same location or distributed to multiple locations geographically. The 3D printing hardware in this illustration is strictly intended to be illustrative.
FIG. 18 illustrates a website containing an example of a user interface allowing the design of a custom motorcycle gas tank, wherein the gas tank is being embossed, by 3D displacement mapping, with flames such that the gas tank, which was originally not embossed with the 3D flames, is considered to represent a customized or personalized product. The product can be produced by additive fabrication means, directly from the 3D data after being routed through said made-to-order digital manufacturing system and said resultant product can then be finished and shipped to said customer without molds, tooling or much of the labor required in traditional methods. The product, in this case being a gas tank, can still meet all form, fit and function requirements of said product including mating surfaces and other necessary features and also convey the desired characteristics of the user/customer design session.
In the foregoing specification, embodiments of the present invention, e.g. a Made-To-Order Digital Manufacturing Enterprise System have been described as applicable to an implementation anticipating internet-based ordering or touch-panel Kiosk-based ordering of custom or made-to-order 3D products of the types outlined herein, where the special advantages of the methods and systems are very attractive for both users/customers and manufacturers. However, embodiments of the present invention may be applied to the sale and/or manufacture of many products of a homogeneous or heterogeneous nature and are limited only by the production capabilities of current or future additive fabrication methodologies and equipment, as well as the ability to adequately describe a product or products as 3D models and render such 3D objects for a user/customer so that the manipulation and controls of the system have meaning to the user or customer of the system and clearly defined manufacturability parameters. Furthermore, the preceding specification has described with reference to specific embodiments thereof. However, various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. The specifications and drawings are, accordingly, to be regarded in an illustrative sense rather than a restrictive sense.

## Claims

1. A customer-driven method for designing and producing a three-dimensional object, the method comprising the steps of:
receiving a selection of a base three-dimensional object from a customer device in communication with a central device;
displaying on the customer device a base three-dimensional model derived from base-three dimensional data wherein the base three-dimensional model corresponds directly to the base three-dimensional object;
receiving at least one custom modification to the base three-dimensional model from the customer device, modifying the base three-dimensional data to form modified three- dimensional data, and preparing a modified three-dimensional model corresponding to a modified three-dimensional object determined by the base three-dimensional object as modified by said at least one custom modification;
displaying the modified three-dimensional model on the customer device, wherein the modified three-dimensional model corresponds directly to the modified three-dimensional object;
receiving confirmation to produce the modified three-dimensional object from the customer device;
determining a respective capacity, a quality rating, and a location of a plurality of manufacturers;
selecting at least one of the manufacturers for receipt of the modified three-dimensional image model based on the respective capacity, the quality rating, and the location of said at least one of the manufacturers; and
transmitting the modified three-dimensional data directly from the central device to the at least one respective manufacturer device associated with said at least one of the manufacturers selected for automatic production of the modified three-dimensional object, using and corresponding directly to the modified three-dimensional data.

2. The method of claim 1, wherein the step of receiving said at least one custom modification from the customer device comprises:
providing an interactive design interface comprising at least one design tool to the customer device for permitting modifications to the base three-dimensional image model;
receiving at least one selection from the customer device using the interactive design interface; and
converting said at least one selection to a modification of the base three-dimensional model to prepare the modified three-dimensional model.

3. The method of claim 1, wherein the steps of receiving said at least one custom modification from the customer device and transmitting the modified three-dimensional model to the customer device comprise:
receiving a first custom modification to the base three-dimensional model from the customer device and preparing a first iterative modified three-dimensional model;
transmitting the first modified three-dimensional model from the central device to the customer device for display;
receiving at least one additional custom modification to the first modified three-dimensional model from the customer device and preparing at least one additional iterative modified three-dimensional model; and
transmitting said at least one additional iterative modified three-dimensional model from the server to the customer device for display.

4. The method of claim 1, further comprising the step of adding traveler information to the modified three-dimensional model to enable tracking of the modified three-dimensional model, the modified three-dimensional object, or combinations thereof, wherein the traveler information comprises a portion of the modified three-dimensional model that directly corresponds to a physical feature of the modified three-dimensional object.

5. The method of claim 1, wherein the step of receiving said at least one custom modification by the central device further comprises determining, by the central device, if said at least one custom modification deviates from a preselected parameter associated with the base three-dimensional object and preventing application of said at least one custom modification to the base three-dimensional model, transmitting a notification to the customer device, or combinations thereof, if said at least one custom modification deviates from the preselected parameter.

6. The method of claim 1, wherein the step of receiving said at least one custom modification from the customer device comprises receiving a modification to a shape of the base three-dimensional model, wherein the modification to the shape corresponds to an addition or removal of material to or from the base three-dimensional object.

7. The method of claim 1, wherein the step of receiving said at least one custom modification from the customer device comprises receiving a non-predefined modification created using the customer device.

8. A system for designing and producing a three-dimensional object, the system comprising:
a central device having a plurality of base three-dimensional models accessible therefrom, each corresponding to a base three-dimensional object;
a customer device in communication with the central device;
a manufacturer device in communication with the central device;
an interactive design interface associated with the central device, the customer device, or combinations thereof, wherein the interactive design interface comprises computer instructions for permitting selection of a modification to a base three-dimensional model by the customer device;
imaging computer instructions associated with the central device for producing a modified three-dimensional model corresponding to a modified three-dimensional object using the base three-dimensional model and a selection from the interactive design interface;
capacity computer instructions for determining a respective capacity, a quality rating, and a location a plurality of manufacturers and selecting at least one of the manufacturers for receipt of the modified three-dimensional model based on the respective capacity, the quality rating, and the location of said at least one of the manufacturers;
confirmation computer instructions associated with the central device for receiving a confirmation of the modified three-dimensional model and transmitting the modified three-dimensional model directly from the central device to the respective manufacturer device associated with said at least one of the manufacturers selected for automatic production of the modified three-dimensional object, corresponding directly to the modified three-dimensional model.

9. The system of claim 8, wherein the interactive design interface comprises a design tool having computer instructions for receiving the selection from the customer device and converting the selection to a modification of the base three-dimensional model to form the modified three-dimensional model.

10. The system of claim 8, wherein the confirmation computer instructions are configured to add traveler information to the modified three-dimensional model to enable tracking of the modified three-dimensional model, the modified three-dimensional object, or combinations thereof, and wherein the traveler information comprises a portion of the modified three-dimensional model that directly corresponds to a physical feature of the modified three-dimensional object.

11. The system of claim 8, further comprising a preselected parameter associated with a base three-dimensional object associated with the central device, and computer instructions for determining if the modification deviates from the preselected parameter and preventing application of said at least one custom modification to the base three-dimensional model, transmitting a notification to the customer device if the modification deviates from the preselected parameter, or combinations thereof.

12. The system of claim 8, wherein the computer instructions of the interactive design interface are configured to receive a modification to a shape of the base three-dimensional model, and wherein the modification to the shape corresponds to an addition or removal of material to or from the base three-dimensional object.

13. The system of claim 8, wherein the computer instructions of the interactive design interface further permit creation by the customer device of at least one non-predefined modification.

14. A method for designing and producing a three-dimensional object, the method comprising the steps of:
transmitting a base three-dimensional model from a central device to a customer device for display, wherein the base three-dimensional model corresponds directly to a base three-dimensional object;
receiving at least one custom modification to the base three-dimensional model from the customer device and modifying the base three-dimensional model using said at least one custom modification to form a modified three-dimensional model, wherein the modified three-dimensional model corresponds directly to a modified three-dimensional object determined by the base three-dimensional object as modified by said at least one custom modification;
transmitting the modified three-dimensional model from the central device to the user device for display;
determining a respective capacity, a quality rating, and a location of a plurality of manufacturer devices;
selecting at least one of the manufacturers for receipt of the modified three-dimensional model based on the respective capacity, the quality rating, and the location of said at least one of the manufacturers;
and transmitting the modified three-dimensional model from the central device to a respective manufacturer device associated with said at least one of the manufacturers selected for production of the modified three-dimensional object by the manufacturer device, using and corresponding directly to the modified three-dimensional model.

15. The method of claim 14, wherein the step of receiving said at least one custom modification from the user device comprises receiving a change in a shape of the base three-dimensional model corresponding to an addition or removal of material to or from the base three-dimensional object.

16. The method of claim 14, wherein the step of transmitting the modified three-dimensional data from the central device to the manufacturer device comprises transmitting the modified-three dimensional data directly from the central device to the manufacturer device for automatic production of the modified three-dimensional object.

17. The method of claim 14, further comprising the step of adding traveler information to the modified three-dimensional model to enable tracking of the modified three-dimensional model, the modified three-dimensional object, or combinations thereof, wherein the traveler information comprises a portion of the modified three-dimensional model that directly corresponds to a physical feature of the modified three-dimensional object.