Patent Document ID: 10073440
Application ID: 15895478
Patent Status: 1

Claim One:
1. A method for the design and manufacture of a replica composite object based on an original object, the manufacture accomplished using additive manufacturing, the method comprising: identifying one or more physical properties of an original object; determining one or more physical properties of a plurality of base materials; determining one or more physical properties of a plurality of bodies; comparing the identified physical properties of the original object with the physical properties of the plurality of base materials and the physical properties of the plurality of bodies; determining one or more desired physical properties of a replica composite object based on the identified one or more physical properties of the original object, the replica composite object including at least one unit; dividing the at least one unit into a plurality of subunits, each subunit having tunable dimensions; for each subunit, selecting at least one of the plurality of base materials and at least one of the plurality of bodies to match the one or more desired physical properties of the replica composite object with the identified one or more physical properties of the original object; generating a 3-dimensional model of the replica composite object based on a structure of the original object, the replica composite object including the selected at least one of the plurality of base materials and at least one plurality of bodies for each subunit; discretizing at least one of the plurality of subunits into a finite number of single or multidimensional elements, each element having one or more associated physical properties; calculating the one or more associated physical properties for the at least one unit of the replica composite object wherein the one or more associated physical properties are based on the identified physical properties of the original object; comparing the one or more associated physical properties for the at least one unit of the replica composite object with the identified physical properties of the original object; if the respective physical properties of the replica composite object and the original object differ by more than a tolerance value, optimizing the one or more desired physical properties of the replica composite object by adjusting the physical properties of the at least one unit of the replica composite object, wherein the physical properties are based on at least one base material or a combination of one or more base materials and one or more bodies; and instructing an additive manufacturing system to generate the replica composite object having a combination of physical properties that substantially equates to the identified physical properties of the original object.