Efficient Metal Die Manufacturing with Composite 3D Printing
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Summary
Problems
Traditional additive manufacturing methods, such as FDM and subtractive manufacturing, face challenges in producing large, strong, and stiff metal dies with complex geometries efficiently, as they require extensive printing and debinding times, and often compromise on strength and stiffness due to the use of infill patterns.
Innovation solutions
The method involves 3D printing a metal object with a solid outer shell and a patterned infill, followed by infiltration with a dry metal powder and sintering, which allows for the creation of composite structures with high density and strength, enabling the production of large metal dies with dimensions exceeding 1.5 inches without cracks or deformations.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If traditional subtractive manufacturing methods are used to create metal dies, then the manufacturing process is well-established and reliable, but the process is time-consuming, labor-intensive, and compromises strength and stiffness
Why choose this principle:
The die is divided into two distinct components: a 3D-printed outer shell providing complex geometry and a powder-filled infill providing structural strength. This segmentation allows each component to fulfill its specific function optimally while resolving the contradiction between manufacturing efficiency and mechanical strength.
Principle concept:
If traditional subtractive manufacturing methods are used to create metal dies, then the manufacturing process is well-established and reliable, but the process is time-consuming, labor-intensive, and compromises strength and stiffness
Why choose this principle:
The invention creates a composite structure combining the 3D-printed metal shell with infiltrated metal powder. This composite approach enables the die to achieve high strength and stiffness (exceeding 90% of theoretical wrought density) while benefiting from the efficiency of additive manufacturing.
Application Domain
Data Source
AI summary:
The method involves 3D printing a metal object with a solid outer shell and a patterned infill, followed by infiltration with a dry metal powder and sintering, which allows for the creation of composite structures with high density and strength, enabling the production of large metal dies with dimensions exceeding 1.5 inches without cracks or deformations.
Abstract
Metal composites, tooling and methods of additively manufacturing these are disclosed. Metal objects and structures as provided herein are additively manufactured from metal having an infill pattern infiltrated with a metal powder. Also provided herein are methods of forming such objects and structures. Methods include additively manufacturing a metal structure having an interior printed using an infill. Steps can further include infiltrating the printed infill of the structure with a powder metal thereby forming a composite.