3D metal part printing of refiner segments

Abstract

A method for additive machining of a refiner plate segment having a feature pattern includes manufacturing a refiner plate segment having a partial feature pattern from a first material, optically scanning the refiner plate segment to identify locations of features of the partial feature pattern, automatically generating a first code from data obtained from the optical scan for three-dimensional (3D) printing of a second material at first designated locations of the partial feature pattern, and 3D printing of the second material at the designated locations.

Description

[Background technology]

[0001] Unless otherwise indicated herein, the subject matter described in this section is not prior art to the claims of this application and is not admitted to be prior art by inclusion in this section.

[0002] As part of the papermaking process, lignocellulosic materials, such as wood chips and other fibrous materials, are refined by mechanical refiners. Refiners for processing fibrous materials typically include refiner disks, one of which rotates relative to the other. Other types of disks, such as disperser disks, may perform other steps as part of the papermaking process. Each disk may include multiple segments, which, when assembled into the mechanical refiner, form a complete disk.

[0003] The manufacture of disk segments, also referred to as plate segments, is conventionally performed using a casting process. Refiner plate segments are typically cast from a single piece of material. The single piece may be a relatively soft material that minimizes breakage but wears quickly. Alternatively, the single piece may be a relatively hard material that reduces wear but is more susceptible to breakage. Summary of the Invention

[0004] The present invention relates to a method of manufacturing plate segments, and more particularly, but not exclusively, to a method of manufacturing plate segments, such as refiner plate segments, disperser plate segments, flinger plate segments, etc., using additive machining processes.

[0005] According to various aspects of the present disclosure, a method is provided for additive machining of a refiner plate segment having a feature pattern. In some aspects, the method may include steps including fabricating a refiner plate segment having a partial feature pattern from a first material, optically scanning the refiner plate segment to identify locations of features within the partial feature pattern, automatically generating a first code for three-dimensional (3D) printing of a second material at a first designated location of the partial feature pattern from data obtained from the optical scan, and 3D printing of the second material at the designated location.

[0006] According to various aspects of the present disclosure, a method is provided for additive machining of a blank refiner plate segment without a feature pattern. In some aspects, the method may include steps including manufacturing a blank refiner plate segment without the feature pattern from a first material, generating code for 3D printing the feature pattern from design data for the feature pattern, and 3D printing the feature pattern with a second material on the blank refiner plate segment to form the refiner plate segment.

[0007] According to various aspects of the present disclosure, a method is provided for repairing a feature pattern of a refiner plate segment using additive machining. In some aspects, the method may include steps including obtaining a previously used refiner plate segment including a first material, performing a planarization step to obtain a flat surface on top surfaces of features of the feature pattern, performing an optical scan of the refiner plate segment to identify locations of the features of the feature pattern, automatically generating code for 3D printing of a second material at designated locations of the feature pattern from data obtained from the optical scan, and 3D printing of the second material at the designated locations.

[0008] According to various aspects of the present disclosure, a method for additive machining of a refiner plate segment is provided. In some aspects, the method may include steps including obtaining design data for the refiner plate segment, generating code for 3D printing of a refiner plate segment substrate, 3D printing the refiner plate segment substrate with a first material, generating code for 3D printing of a feature pattern from the refiner plate segment design data, and 3D printing the feature pattern with a second material.

[0009] BRIEF DESCRIPTION OF THE DRAWINGS Aspects of the various embodiments will become more apparent by way of example only and with reference to the accompanying drawings, in which: FIG. [Brief description of the drawings]

[0010] [Figure 1] 1A-1C show examples of feature pattern bars fabricated on a substrate in accordance with various aspects of the present disclosure. [Figure 2A] 1A-1C show examples of feature pattern bars fabricated on a blank plate segment according to various aspects of the present disclosure. [Figure 2B] 1A-1C show examples of feature pattern bars fabricated on a blank plate segment according to various aspects of the present disclosure. [Figure 2C] 1A-1C show examples of feature pattern bars fabricated on a blank plate segment according to various aspects of the present disclosure. [Figure 2D] 1A-1C show examples of feature pattern bars fabricated on a blank plate segment according to various aspects of the present disclosure. [Figure 2E] 1A-1C show examples of feature pattern bars fabricated on a blank plate segment according to various aspects of the present disclosure. [Diagram 3] 1 is a flow chart illustrating an example method for additive machining of a plate segment having a feature pattern, according to various aspects of the present disclosure. [Figure 4]1 is a flow chart illustrating an example method of additive machining of a blank plate segment substrate having no feature pattern, according to various aspects of the present disclosure. [Diagram 5] 1 is a flowchart illustrating an example method of repairing a feature pattern in a plate segment using additive machining, in accordance with various aspects of the present disclosure. [Figure 6] 1 is a flowchart illustrating an example method for additive machining of a plate segment, according to various aspects of the present disclosure. [Figure 7] 1 is a flow chart illustrating an example method for additive machining of a plate segment having a partial feature pattern, according to various aspects of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Although specific embodiments are described, these embodiments are presented by way of example only and are not intended to limit the scope of the invention. The devices, methods and systems described herein may be embodied in various other forms. Furthermore, various omissions, substitutions and changes in the form of the exemplary methods and systems described herein may be made without departing from the scope of protection.

[0012] Like reference numerals designate corresponding parts throughout the several views unless otherwise stated. Although the drawings depict embodiments of various features and components according to the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated to better illustrate embodiments of the present disclosure, and such illustration should not be construed as limiting the scope of the present disclosure.

[0013] Unless otherwise expressly stated herein, the following rules of interpretation shall apply herein: (a) all words used herein shall be construed as to gender or number (singular or plural) where the context so requires, (b) the singular terms "a," "an," and "the" used in this specification and the appended claims include plural references unless the context clearly dictates otherwise, (c) the term "about" preceding a stated range or value indicates an approximation within the deviation of the range or value that is known or expected in the art from measurement, (d) the words "herein," "hereby" and "hereby" shall mean any and all words that are intended to be understood as meaning, and shall not be construed as meaning, in any manner whatsoever, including, but not limited to, any words that are intended to be understood as meaning, in any manner whatsoever, including, but not limited to, any words that are intended to be understood as, but not limited to, any words that are intended to be understood as, in any manner whatsoever, including ... The words "hereto," "hereinbefore," and "hereinafter" and words of similar import refer to the specification as a whole and not to any particular paragraph, claim, or other subdivision, unless otherwise specified; (e) the explanatory headings are for convenience only and do not control or affect the meaning or construction of any part of this specification; (f) "or" and "any" are not exclusive, and "include" and "including" are not limiting. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms (i.e., meaning "including but not limited to").

[0014] The recitation of ranges of values ​​herein is merely intended to serve as a shorthand method of individually referring to each separate value within the range and any subrange therebetween, unless otherwise expressly stated herein. Each separate value within a recited range is incorporated into the specification or claims as if each separate value were individually recited herein. When a specific range of values ​​is provided, it is understood that each value between the upper and lower limits of that range, to the tenth of the unit of the lower limit, and any other stated or intervening value of that recited range or subrange, is included herein, unless the context clearly indicates otherwise. All subranges are also included. The upper and lower limits of these smaller ranges are also included therein, subject to any specifically and explicitly excluded limits in the recited range.

[0015] Aspects of the present disclosure may provide a method of manufacturing plate segments (generally referred to herein as refiner plate segments or plate segments), such as refiner plate segments, disperser plate segments, flinger plate segments, and the like, using a 3D printing process (also referred to herein as an additive machining process) to perform additive machining steps. The disclosed methods may also be used to repair worn or damaged refiner plate segments. Additive machining processes may be utilized to manufacture plate segments having two or more materials, for example, but not limited to, a relatively soft substrate material that minimizes breakage combined with a relatively hard material that reduces wear to the feature pattern.

[0016] According to some aspects of the present disclosure, optical scanning, e.g., 3D laser scanning, of a plate segment having a feature pattern may be used to obtain feature pattern data for 3D printing additional material onto features of an existing feature pattern. The plate segment having the feature pattern may be manufactured in a conventional manner, e.g., by casting or other conventional manufacturing methods. The feature pattern may include, for example, but is not limited to, bars, grooves, dams, etc. In some cases, features of the feature pattern may be dimensioned such that the features are wider at the top surface than at the base of the features.

[0017] In some cases, the features of the feature pattern may be flattened so that the top surface of each feature lies in the same plane. The plate segments may be optically scanned, for example, with a 3D laser scanning device or other imaging device, such as 2D or 3D digital photography by a camera or similar, or other types of scanning devices, such as radar-based scanning devices, to identify the dimensions and locations of the features of the feature pattern. Scanning can eliminate the need to obtain design data to find precise dimensions to determine the location and size of the features, and can also eliminate the need for precise placement of the plate segments to perform the 3D printing process.

[0018] Based on data obtained from the scanning process, the top surface of the feature may be identified, and the type and thickness of material to add at the desired location may be selected by an operator. For example, the refiner plate substrate and feature pattern may be cast from a relatively ductile material to minimize breakage, but additional material may be added to selected portions of the feature pattern to increase hardness and minimize wear.

[0019] Programming code for 3D printing additional material on selected surfaces of the feature pattern may be automatically generated from the data obtained by scanning the plate segments. The programming code may be, for example, code for programming a computer numerically controlled (CNC) 3D printing device. The 3D printing device may deposit and melt / fuse the additional material on top of the features, gradually increasing the height of the features to a specified height based on the design specifications and the pattern identified by the scan. In some implementations, the 3D printing may occur while the scan is occurring.

[0020] Additional material may be added on top of an existing feature. It is understood that additive machining processes may be used to add one, two, three, or more additional materials. Although 3D printing is described throughout this disclosure as a method for additive machining, material may be added using any suitable method, such as welding, sintering, gluing, forging, 3D printing, etc. This process may add between about 0.5 mm and 5 mm of material to the top surface of the feature. The added material may be of the same composition as the plate segment substrate material, or may be a different material, such as a harder wear-resistant material deposited on a softer, more elastic (e.g., breakage-resistant) material used for the plate segment substrate and the lower portion of the feature. The resulting plate segment may be used directly and / or may be heat treated and / or reground to provide a flat, tapered, conical, cylindrical surface.

[0021] One process technique for use with the concepts of the present invention may be direct metal laser deposition (DMLD). DMLD may be used with metal powder or metal wire as the deposition source. In some cases, metal wire may provide better precision in the formation of features and may provide improved surface finishes compared to metal powder. DMLD uses a laser to melt metal powder or wire onto a substrate, which may be, according to various aspects of the present disclosure, a refiner plate blank segment, a worn refiner plate segment, or a partial bar height refiner plate segment where only the top of the bar differs from the substrate, e.g., a harder material may be added. Many variations of this process exist and may be known, for example, but not limited to, laser cladding or directed energy deposition.

[0022] Laser Engineered Net Shaping (LENS) is another process technique that may be used with the concepts of the present invention. LENS may be applicable where a damaged part is repaired by adding material to the damaged area.

[0023] Tungsten inert gas (TIG) welding, also known as gas tungsten arc welding (GTAW), is yet another additive machining process technique that may be used with the concepts of the present invention. TIG welding also uses wire as a deposition source for 3D additive manufacturing.

[0024] Additive machining techniques may use materials the same or similar to those used in the manufacture of refiner plates. While the present disclosure provides examples of materials that may be used in additive machining process techniques, a wide range of other materials, existing or later developed, may be used to provide the improved properties and performance of the various embodiments. Using additive machining techniques, multi-material bar designs may be realized with refiner plate features that may be softer at either the base and / or center of the feature depending on the requirements of the application. The multi-material bar design may provide improved wear resistance from the top or outer layers along with the toughness of the softer material at the base.

[0025] The base (e.g., lower portion) of the bar may be made from a ductile material such as austenitic stainless steel or other alloys with a hardness of less than 45HRC, e.g., less than 42HRC or less than 40HRC. The material added to the top of the bar may be harder, e.g., greater than 45HRC, 50HRC, or 55HRC. The material may be, for example, but not limited to, martensitic stainless steel or high carbon white cast iron. Alternatively, more exotic materials may be used, including titanium, tool steel, and any other material that can be fused to the base material and provides good wear resistance.

[0026] In some cases, additive machining techniques may be used to manufacture features, such as bar / groove patterns, on a blank refiner plate disc or segment. The refiner plate disc or segment may be manufactured, for example, by casting or otherwise, according to typical manufacturing processes. The manufactured disc or segment may have a blank surface, for example, a surface without refining features, on which additive machining processes may be used to manufacture refining features. Refining features may include any features utilized to process raw materials in a refinery machine.

[0027] The placement of the blank segment machining device may be visually accurately identified to enable additive machining without the need to precisely set up the blank part on the machine. Visual measurements may be made via digital photography, 3D photography / imaging, laser scanning, radar scanning, or other methods that can precisely digitally define the dimensions of the blank part and position the blank part on the additive machining device to precisely enable metal to be added to the blank disc or segment. Programmed feature designs such as bar / groove designs may be printed onto the surface of the blank disc segment. The entirety of the refining bars and / or other features may be printed by metal deposition from a programmed image. The bars and / or other features may be constructed using one material or multiple different materials.

[0028] The blank segments may be formed from any type of metal to which the alloy used to form the bar can fuse. The hardness / softness of the blank segments may depend on the application. When blank segments without bars are used, the bars can be formed from a single alloy or multiple alloys. When the bars are formed from multiple alloys, the top, outer portion, and / or part of the sides or edges can be made of a harder material.

[0029] FIG. 1 is a diagram illustrating an example of a feature pattern bar 120 fabricated on a substrate 160 according to various aspects of the disclosure. Referring to FIG. 1, the substrate 160 and the base of the bar 120 may be formed of the same material, for example, a relatively ductile alloy 124, such as an austenitic stainless steel or another alloy. The substrate 160 and the base of the bar 120 may be fabricated using a conventional process, for example, but not limited to, a casting process or other process. Alternatively, the substrate 160 and the base of the bar 120 may be fabricated using additive machining process techniques. A wear-resistant alloy 122, for example, a martensitic stainless steel or another alloy, may be deposited on the top of the bar 120 using an additive machining process. It should be understood that one, two, three, or more additional materials may be added using an additive machining process. In some implementations, the substrate and the base of the bar may be formed from a combination of multiple materials, for example, alloys.

[0030] 2A-2E are diagrams illustrating examples of feature pattern bars fabricated on blank plate segments according to various aspects of the disclosure. With reference to FIG. 2A, feature pattern bar 210 may be formed from a single alloy 212 on a blank segment 260 (e.g., substrate). Using a DMLD process or other additive machining process technique, a bar formed from, for example, a martensitic stainless steel or other alloy may be deposited on a blank segment fabricated from, for example, an austenitic stainless steel or other alloy. In some implementations, the substrate may be formed from a combination of multiple materials, for example alloys.

[0031] FIG. 2B shows an example of a feature patterned bar 220 fabricated with two alloys 222, 224 on a plate segment 262. The base of the bar 220 may be formed from a relatively ductile alloy 224, e.g., an austenitic stainless steel or another alloy or combination of alloys, and a harder, more wear-resistant alloy 222, e.g., a martensitic stainless steel or another alloy, is deposited on the top of the bar 220. In some cases, the plate segment 262 may be a blank plate segment (e.g., a substrate) and the feature patterned bar 220 may be fabricated on the blank plate segment 262. In some cases, the feature patterned bar 220 may be prefabricated on the plate segment 262 with the ductile alloy 224, e.g., by a casting process or another process. The wear-resistant alloy 222 may be fabricated using an additive machining process. In some cases, plate segment 262 may be a previously used plate segment, with feature pattern bar 220 having ductile alloy 224 present on the used plate segment. In some implementations, the substrate may be formed from a combination of multiple materials, such as alloys. Wear resistant alloy 222 may be manufactured using additive machining processes. It should be understood that additive machining processes may be used to add one, two, three, or more additional materials.

[0032] FIG. 2C shows an example of a feature pattern bar 230 manufactured with three alloys 232, 233, 234 on a plate segment 264. The base of the bar 230 may be formed from a relatively ductile alloy 234, such as an austenitic stainless steel or other alloy, and a first alloy 232 is deposited on the top of the bar 230. This first deposited alloy may have a higher wear resistance than the bar alloy 234, or may be an intermediate alloy that aids in proper adhesion between the bar alloy 234 and the top more wear resistant alloy 233. A second alloy 233 different from the first alloy 232, such as a martensitic stainless steel or other alloy, may be deposited on the first alloy 232. In some cases, the plate segment 264 may be a blank plate segment, and the feature pattern bar 234 may be manufactured on the blank plate segment 264. In some cases, the feature pattern bar 234 may be pre-fabricated on the plate segment 264 with the ductile alloy 234, for example, by a casting process or another process. The wear-resistant alloy 233 may be fabricated using an additive machining process. In some cases, the plate segment 264 may be a previously used plate segment, and the feature pattern bar 230 has the ductile alloy 234 present on the used plate segment. The wear-resistant alloy 233 may be fabricated using an additive machining process. In some implementations, the substrate may be formed from a combination of multiple materials, for example alloys. It should be understood that one, two, three, or more additional materials may be added using an additive machining process.

[0033] FIG. 2D shows another example of a feature pattern bar 240 manufactured with two alloys 242, 244 on a plate segment 266. In FIG. 2D, an inner portion of the bar 240 may be formed from a relatively ductile alloy 244, e.g., an austenitic stainless steel or another alloy, and a harder, more wear-resistant alloy 242, e.g., a martensitic stainless steel or another alloy, is deposited on an outer portion of the bar 240. In some cases, the plate segment 266 may be a blank plate segment, and the feature pattern bar 240 may be manufactured on the blank plate segment 266. In some cases, the feature pattern bar 240 may be pre-manufactured on the plate segment 266 with the ductile alloy 244, e.g., by a casting process or another process. The wear-resistant alloy 242 may be manufactured using an additive machining process. In some cases, the plate segment 266 may be a previously used plate segment, and the feature pattern bar 240 has the ductile alloy 244 present on the used plate segment. The wear-resistant alloy 242 may be manufactured using additive machining processes. In some embodiments, the substrate may be formed from a combination of multiple materials, such as alloys. It is understood that additive machining processes may be used to add one, two, three, or more additional materials.

[0034] FIG. 2E illustrates yet another example of a feature patterned bar 250 fabricated with two alloys 252, 254 on a plate segment 268. As illustrated in FIG. 2E, one or more sides of the bar 250 may be formed from a relatively ductile alloy 254, e.g., an austenitic stainless steel or another alloy, and a harder, more wear-resistant alloy 252, e.g., a martensitic stainless steel or another alloy, is deposited on the remaining portions of the bar 250. In some cases, the plate segment 268 may be a blank plate segment, and the feature patterned bar 250 may be fabricated on the blank plate segment 268. In some cases, the feature patterned bar 250 may be prefabricated on the plate segment 268 with the ductile alloy 254, e.g., by a casting process or another process. The wear-resistant alloy 252 may be fabricated using an additive machining process. In some cases, plate segment 268 may be a previously used plate segment, with feature pattern bar 250 having ductile alloy 254 present on the used plate segment. In some implementations, the substrate may be formed from a combination of multiple materials, such as alloys. Wear resistant alloy 252 may be manufactured using additive machining processes.

[0035] In some cases, additive machining processes may be performed on the top surfaces of features in an existing design, such as, for example, but not limited to, refining bars, dams, or other features. Features may be located and precisely identified, for example, using 3D laser scanning or other optical scanning devices, acoustic-based scanning devices, radar-based scanning devices, etc., and location and dimensional measurements converted into a 3D printing program. Additive machining may be used to deposit material at the identified locations based on the location of the disk or segment on the machining table, without the need for precise setup. Optical scanning techniques may be particularly advantageous for purpose-built segments that are adapted to repair previously used refiner disks or segments that have been prepared, for example, by resurfacing or flattening to provide features of uniform height, or to add harder material to the top and / or edges of the refining bars.

[0036] In some cases, sintering and / or heat treating of the part after or during additional machining may be performed to ensure desired material properties such as hardness is achieved. Optional surface quality treatments via shot peening, sand blasting, or any other suitable means may also be performed. Optionally, surface grinding may be performed on the tops of the features to ensure flatness of the final part and sharp edges on the features. Electropolishing may also be used if a very smooth surface on the features is desired.

[0037] FIG. 3 is a flow chart illustrating an example of a method 300 for additive machining of a plate segment having a feature pattern, according to various aspects of the disclosure. Referring to FIG. 3, in block 310, a plate segment having a partial feature pattern is manufactured. The plate segment may be, for example, but not limited to, a refiner plate segment, a disperser plate segment, a flinger plate segment, or other plate segment. The plate segment may be manufactured based on design data specifying features of the feature pattern and the location of the features where additive machining may be performed. The plate segment may be a flat refiner plate segment, a cylindrical refiner plate segment, a conical refiner plate segment, or a one-piece roundel. The partial feature pattern may include, but is not limited to, bars, grooves, dams, channels, or other features. The plate segment may be manufactured using a casting process or other process. The partial feature pattern may be a feature pattern having features with heights determined from a plate segment substrate. The height of the partial feature pattern may be less than the designed height of the features. In some cases, features of a feature pattern may be dimensioned such that the feature is wider at the top surface than at the base of the feature.

[0038] An optional planarization step may be performed at block 320. The plate segments may be machined to obtain a flat surface such that the top surfaces of the features in the partial feature pattern lie in the same plane. In the case of curved plate segments, the optional planarization step results in the top surfaces of the features in the partial feature pattern having the same height relative to the base of the plate segment.

[0039] In block 330, the plate segment may be scanned to determine the location and height of features of the partial feature pattern. The plate segment may be scanned, for example, but not limited to, by a 3D laser scanning device or other optical scanning device, an acoustic-based scanning device, a radar-based scanning device, etc. The scanning process may identify the periphery of the plate segment and generate a three-dimensional map that defines the location and dimensions of the features of the partial feature pattern relative to the periphery of the plate segment. Thus, in this case, no specific alignment of the plate segment is required. In some cases, the location and dimensions of the features of the partial feature pattern may be obtained from the design data of the plate segment. Alternatively, the plate segment may be placed in a predetermined manner in the 3D printing device. For example, the plate segment may be placed in the 3D printing device via a fixture set in a known position and orientation.

[0040] At block 340, an intermediate material may be optionally applied. In some cases, the intermediate material may be applied to promote stronger bonding between the material from which the plate segment is manufactured and the more wear-resistant material that is added to the features of the partial feature pattern. When the intermediate material is applied, an optional step may be performed to generate programming code for 3D printing of the intermediate material at the designated feature location. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device. The intermediate material may be applied to achieve a secure bond of the first material to the second material. The features to which the intermediate material is applied may be selected by an operator. The programming code for 3D printing of the intermediate material may be automatically generated from the 3D scan data and the selected features.

[0041] When the intermediate material is applied, an optional step of 3D printing the intermediate material at the specified feature locations may occur in block 350. Based on the 3D scan data and programming code generated from the selected features, the intermediate material may be 3D printed onto the features at the identified locations.

[0042] An optional sintering step may be performed when applying the intermediate material at block 360. The sintering step may be performed to fuse the intermediate material to the first material, thereby increasing the strength and structural integrity of the material. Sintering may occur when the intermediate material is printed onto the identified features, for example, using a laser sintering process. Alternatively or additionally, sintering may be accomplished by heat treating the plate segments.

[0043] At block 370, programming code for 3D printing of a second material at the specified feature location may be generated. In some cases, the program code for 3D printing may be available from the design data of the plate segment. The second material may be a more wear-resistant material that is added to the identified feature of the partial feature pattern. In some cases, the second material may be the same as the first material. The feature to which the second material is applied may be selected by an operator. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device. The code for 3D printing of the second material may be automatically generated from the 3D scan data and the selected feature. In some cases, two or more additional materials may be 3D printed at the specified location based on the code for 3D printing of the second material.

[0044] At block 380, a process of 3D printing a second material at the designated feature location may occur. Based on the 3D scan data and the programming code generated from the selected feature, a second material may be 3D printed onto the feature at the identified location. It should be understood that additive machining processes may be performed for the addition of more than one second material.

[0045] At block 390, an optional sintering step may be performed. The sintering step may be performed to fuse the second material to the first material (or intermediate material, if used), thereby increasing the strength and structural integrity of the material. Sintering may be performed when the second material is printed onto the identified features, for example, using a laser sintering process. Alternatively or additionally, sintering may be achieved by heat treating the plate segments. Optionally, a flattening step may be performed on the plate segments.

[0046] The specific steps illustrated in FIG. 3 provide a specific method 300 of additive machining of a plate segment having a feature pattern according to an embodiment of the present disclosure. Other sequences of steps may be performed according to alternative embodiments. For example, alternative embodiments of the present disclosure may perform the steps outlined above in a different order. Additionally, the individual steps illustrated in FIG. 3 may include multiple sub-steps that may be performed in various sequences appropriate to the individual step. Additionally, additional steps may be added or removed depending on the particular application.

[0047] According to some aspects of the present disclosure, a 3D printing process may be used to manufacture a feature pattern on a blank plate segment substrate. Rather than manufacturing a plate segment with a feature pattern by a conventional method, such as casting or other conventional manufacturing methods, a blank plate segment substrate may be manufactured without the feature pattern. The feature pattern may then be added via additive machining, such as 3D printing. The feature pattern may be added using the same material as the plate segment substrate, or a different material, such as a hard, wear-resistant material.

[0048] The resulting design data for the feature pattern can be used to generate programming code for 3D printing the feature pattern onto the blank plate segment substrate. The programming code can be, for example, code for programming a computer numerically controlled (CNC) 3D printing device. The 3D printing device can deposit and melt / fuse additional material onto the blank plate segment substrate to generate the feature pattern.

[0049] The method can use a single metallurgy for all added features, which may be the same or different from the plate segment substrate, or can use multiple metallurgies for the bottom and top of the feature, the center (e.g., core) and / or outer surface of the feature, different surfaces / sides of the feature, different parts of the plate segment or different zones of the plate segment, and / or different plate features (e.g., creating dams of different materials), etc. The resulting plate segment may be used directly and / or may be heat treated and / or reground to provide a flat, tapered, conical, or cylindrical surface.

[0050] 4 is a flow chart illustrating an example method 400 of additive machining of a blank plate segment substrate without a feature pattern according to various aspects of the disclosure. Referring to FIG. 4, in block 410, a plate segment substrate without a feature pattern may be manufactured. The plate segment may be a flat refiner plate segment, a cylindrical refiner plate segment, a conical refiner plate segment, or a one-piece round object. The plate segment substrate may be, for example, but not limited to, a refiner plate segment substrate, a disperser plate segment substrate, a flinger plate segment substrate, or other plate segment substrate. The plate segment substrate may be manufactured using a casting process or other process.

[0051] An optional planarization step may be performed at block 415. The plate segment substrate may be machined to obtain a flat surface so that the top surfaces of the plate segment substrate lie in the same plane. For curved plate segments, the optional planarization step may result in a plate segment substrate having a uniform thickness.

[0052] At block 420, programming code for 3D printing of the feature pattern may be generated. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device. The programming code for 3D printing of the feature pattern may be automatically generated from feature pattern design data. In some cases, the programming code for 3D printing of the feature pattern may be available from an existing plate segment design. The feature pattern design data may specify the type and dimensions of features, such as, but not limited to, bars, grooves, dams, etc., and their locations on the plate segment. In some cases, the features of the feature pattern may be dimensioned such that the features are wider at the top surface than at the base of the features.

[0053] At block 425, a process of 3D printing the feature pattern may occur. Based on programming code generated from the feature pattern design data, the feature pattern may be 3D printed onto the plate segment substrate. In some cases, for example, when features are printed from a material different than the material from which the plate segment substrate is manufactured, an intermediate material may be applied to the plate segment substrate in the same pattern as the feature pattern to promote reliable bonding between the plate segment substrate material and the material from which the features of the feature pattern are manufactured.

[0054] At block 430, an optional sintering step may be performed. The sintering step may be performed to fuse the material from which the features are manufactured to the material from which the plate segment substrate is manufactured (or an intermediate material, if used) to increase the strength and structural integrity of the material. Sintering may be performed as the material of the feature pattern is printed onto the plate segment substrate, for example, using a laser sintering process. Alternatively or additionally, sintering may be achieved by heat treating the plate segment (e.g., the plate segment substrate and the 3D printed feature pattern).

[0055] At block 435, an intermediate material may be optionally applied. In some cases, the intermediate material may be applied to promote stronger bonding between the material from which the feature is manufactured and the more wear-resistant material that is added to the feature of the feature pattern. When the intermediate material is applied, an optional step may be performed to generate programming code for 3D printing the intermediate material at the specified feature location. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device. The intermediate material may be applied to ensure bonding of the first material to the second material. The feature to which the intermediate material is applied may be selected by an operator. The programming code for 3D printing of the intermediate material may be automatically generated from the 3D scan data and the selected feature.

[0056] When the intermediate material is applied, an optional step of 3D printing the intermediate material at the specified feature locations may occur at block 440. Based on the 3D scan data and codes generated from the selected features, the intermediate material may be 3D printed onto the features at the identified locations.

[0057] An optional sintering step may be performed when applying the intermediate material at block 445. The sintering step may be performed to fuse the intermediate material to the first material, thereby increasing the strength and structural integrity of the material. Sintering may occur when the intermediate material is printed onto the identified features, for example, using a laser sintering process. Alternatively or additionally, sintering may be accomplished by heat treating the plate segments.

[0058] At block 450, code may be generated for 3D printing of a second material at the specified feature locations. The second material may be a more wear resistant material that is added to the identified features of the partial feature pattern. The features to which the second material is applied may be selected by an operator. The generated code may be code for operating a computer numerically controlled (CNC) 3D printing device. The programming code for 3D printing of the second material may be automatically generated from the feature pattern design data and the selected features.

[0059] At block 455, a process of 3D printing a second material at the specified feature location may be performed. Based on the feature pattern design data and the code generated from the selected feature, the second material may be 3D printed onto the feature at the identified location. It should be understood that additive machining processes may be performed for the addition of more than one second material.

[0060] At block 460, an optional sintering step may be performed. The sintering step may be performed to fuse the second material to the first material (or intermediate material, if used), thereby increasing the strength and structural integrity of the material. Sintering may be performed when the second material is printed onto the identified features, for example, using a laser sintering process. Alternatively or additionally, sintering may be achieved by heat treating the plate segments. Optionally, a flattening step may be performed on the plate segments.

[0061] The specific steps illustrated in FIG. 4 provide a specific method 400 of additive machining of a blank plate segment without a feature pattern according to an embodiment of the present disclosure. Other sequences of steps may be performed according to alternative embodiments. For example, alternative embodiments of the present disclosure may perform the steps outlined above in a different order. Additionally, the individual steps illustrated in FIG. 4 may include multiple sub-steps that may be performed in various sequences appropriate to the individual step. Additionally, additional steps may be added or removed depending on the particular application.

[0062] According to some aspects of the present disclosure, a 3D printing process may be used to repair a feature pattern of a plate segment. After obtaining a previously used plate segment, the features of the feature pattern may be flattened so that the top surface of each feature lies in the same plane. The plate segment may be optically scanned, for example, with a 3D laser scanning device, other imaging device such as 3D digital photography by a camera or similar, or other type of scanning device such as a radar-based scanning device, to identify the dimensions and location of the features of the feature pattern. Scanning may eliminate the need to obtain design data to find the exact dimensions and determine the location and size of the features.

[0063] Based on data obtained from the scanning process, the top surfaces of the features may be identified, and the type and thickness of material to add at the locations to be added may be selected by an operator. For example, the refiner plate substrate and feature pattern may be cast from a relatively ductile material to minimize breakage, but additional material may be added to selected portions of the feature pattern to increase hardness and minimize wear.

[0064] Code for 3D printing additional material on selected surfaces of the feature pattern may be automatically generated from the data obtained by scanning the plate segment. The code may be, for example, code for programming a computer numerically controlled (CNC) 3D printing device for computer controlled metal deposition / printing on top of the bar. The 3D printing device may deposit and melt / fuse additional material on top of the features to gradually increase the height of the features to a specified height based on the design specifications and the pattern identified by the scan. In some cases, features of the feature pattern may be dimensioned such that the features are wider at the top surface than at the base of the features. In some implementations, the 3D printing may occur while the scan is occurring.

[0065] The addition of additional material may be added over existing features. Although 3D printing is described throughout this disclosure as a method for additive machining, material may be added using any suitable method, such as welding, sintering, gluing, forging, 3D printing, etc. This process may add between about 0.5 mm and 5 mm of material over the top of the feature. The added material may be of the same composition as the plate segment substrate material, or it may be a different material, such as a harder wear-resistant material deposited over a softer, more elastic (e.g., breakage-resistant) material used for the plate segment substrate and lower portion of the feature. The resulting plate segment may be used directly and / or may be heat treated and / or reground to produce flat, tapered, conical, cylindrical surfaces.

[0066] 5 is a flow chart illustrating an example 500 of a method for repairing a feature pattern of a plate segment using additive machining, according to various aspects of the disclosure. With reference to FIG. 5, in block 510, a previously used plate segment may be obtained. The previously used plate segment may be a conical or cylindrical plate segment, or may be a one-piece round object. Features (e.g., bars, grooves, dams, etc.) of the previously used plate segment may be worn such that their dimensions no longer comply with manufacturing tolerances.

[0067] At block 520, a planarization step may be performed. The plate segments may be machined to obtain a flat surface such that the top surfaces of the features in the feature pattern lie in the same plane. For curved plate segments, the planarization step results in the top surfaces of the features in the feature pattern having the same height relative to the base of the plate segment.

[0068] At block 530, the plate segment may be scanned to determine the locations of features in the feature pattern. The plate segment may be scanned, for example, but not limited to, by a 3D laser scanning device or other optical scanning device, an acoustic based scanning device, a radar based scanning device, etc. The scanning process may identify the perimeter of the plate segment and generate a three dimensional map that defines the location and dimensions of the features of the feature pattern relative to the perimeter of the plate segment. Thus, no specific alignment of the plate segment is required.

[0069] At block 540, an intermediate material may be optionally applied. In some cases, the intermediate material may be applied to promote stronger bonding between the material from which the plate segments are manufactured and the more wear-resistant material that is added to the features of the feature pattern. When the intermediate material is applied, an optional step may be performed to generate programming code for 3D printing the intermediate material at the designated feature location. The intermediate material may be applied to ensure bonding of the first material to the second material. The features to which the intermediate material is applied may be selected by an operator. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device. The programming code for 3D printing of the intermediate material may be automatically generated from the 3D scan data and the selected features.

[0070] When the intermediate material is applied, an optional step of 3D printing the intermediate material at the specified feature locations may occur at block 550. Based on the programming code generated from the 3D scan data and the selected features, the intermediate material may be 3D printed onto the features at the identified locations.

[0071] An optional sintering step may be performed when applying the intermediate material at block 560. The sintering step may be performed to fuse the intermediate material to the first material, thereby increasing the strength and structural integrity of the material. Sintering may occur when the intermediate material is printed onto the identified features, for example, using a laser sintering process. Alternatively or additionally, sintering may be accomplished by heat treating the plate segments.

[0072] At block 570, programming code may be generated for 3D printing of a second material at the specified feature locations. The second material may be the same as the first material. In some cases, a more wear-resistant material may be added to features identified in the feature pattern. The features to which the second material is applied may be selected by an operator. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device. The programming code for 3D printing of the second material may be automatically generated from the 3D scan data and the selected features.

[0073] At block 580, a process of 3D printing a second material at the designated feature location may occur. Based on the 3D scan data and the programming code generated from the selected feature, a second material may be 3D printed onto the feature at the identified location. It should be understood that additive machining processes may be performed for the addition of more than one second material.

[0074] At block 590, an optional sintering step may be performed. The sintering step may be performed to fuse the second material to the first material (or intermediate material, if used), thereby increasing the strength and structural integrity of the material. Sintering may be performed when the second material is printed onto the identified features, for example, using a laser sintering process. Alternatively or additionally, sintering may be achieved by heat treating the plate segments. Optionally, a flattening step may be performed on the plate segments.

[0075] The specific steps illustrated in FIG. 5 provide a specific method 500 of repairing a feature pattern of a plate segment using additive machining according to an embodiment of the present disclosure. Other sequences of steps may be performed according to alternative embodiments. For example, alternative embodiments of the present disclosure may perform the steps outlined above in a different order. Additionally, the individual steps illustrated in FIG. 5 may include multiple sub-steps that may be performed in various sequences appropriate to the individual step. Additionally, additional steps may be added or removed depending on the particular application.

[0076] According to some aspects of the present disclosure, a 3D printing process may be used to manufacture a complete plate segment including a substrate and a feature pattern. Using the design data obtained for the plate segment, programming code for 3D printing of the plate segment substrate and the feature pattern on the plate segment substrate may be generated. The code may be, for example, code for programming a computer numerically controlled (CNC) 3D printing device. The 3D printing device may deposit and melt / fuse additional material onto the blank plate segment substrate to generate the feature pattern.

[0077] The method can use a single metallurgy for all added features, which may be the same or different from the plate segment substrate, or can use multiple metallurgies for the bottom and top of the feature, the center (e.g., core) and / or outer surface of the feature, different surfaces / sides of the feature, different parts of the plate segment or different zones of the plate segment, and / or different plate features (e.g., creating dams of different materials), etc. The resulting plate segment may be used directly and / or may be heat treated and / or reground to provide flat, tapered, conical, cylindrical surfaces.

[0078] 6 is a flow chart illustrating an example method 600 for additive machining of a plate segment, according to various aspects of the disclosure. With reference to FIG. 6, at block 610, design data for a plate segment may be obtained. The plate segment design data may include design data for a plate segment substrate and a feature pattern for the plate segment. The plate segment may be, for example, but is not limited to, a refiner plate, a disperser plate, a flinger plate, etc., and may include a feature pattern (e.g., bars, grooves, dams, etc.) suitable for a particular application. In some cases, features of the feature pattern may be dimensioned such that the feature is wider at the top surface than at the base of the feature.

[0079] At block 615, programming code for 3D printing of the plate segment substrate may be generated. The programming code for 3D printing of the plate segment substrate may be automatically generated from the plate segment design data. The plate segment substrate design data may specify the overall dimensions of the plate segment substrate, such as, but not limited to, shape, thickness, mounting hole locations, etc. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device.

[0080] At block 620, a process of 3D printing the plate segment substrate may be performed. Based on the code generated from the plate segment design data, the plate segment substrate may be 3D printed. The plate segment substrate may be printed from a first material having properties that may provide resistance to breakage.

[0081] An optional planarization step may be performed at block 625. The plate segment substrate may be machined to obtain a flat surface so that the top surfaces of the plate segment substrate lie in the same plane. For curved plate segments, the optional planarization step may result in a plate segment substrate having a uniform thickness.

[0082] At block 630, programming code for 3D printing of the feature pattern may be generated. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device. The programming code for 3D printing of the feature pattern may be automatically generated from plate segment design data. The plate segment design data may specify, for example, but not limited to, types and dimensions of features such as bars, grooves, dams, etc., and their locations on the plate segment substrate.

[0083] At block 635, a process of 3D printing the feature pattern may occur. Based on programming code generated from the plate segment design data, the feature pattern may be 3D printed onto the plate segment substrate. In some cases, for example, when features are printed from a material different than the material from which the plate segment substrate is manufactured, an intermediate material may be applied to the plate segment substrate in the same pattern as the feature pattern to promote reliable bonding of the plate segment substrate material to the material from which the features of the feature pattern are manufactured.

[0084] At block 640, an optional sintering step may be performed. The sintering step may be performed to increase the strength and structural integrity of the material by fusing the material from which the features are manufactured to the material from which the plate segment substrate is manufactured (or an intermediate material, if used). Sintering may occur as the material of the feature pattern is printed onto the plate segment substrate, for example, using a laser sintering process. Alternatively or additionally, sintering may be achieved by heat treating the plate segment (e.g., the plate segment substrate and the 3D printed feature pattern).

[0085] At block 645, an intermediate material may be optionally applied. In some cases, the intermediate material may be applied to promote a strong bond between the material from which the plate segments are manufactured and the more wear-resistant material that is added to the features of the feature pattern. When the intermediate material is applied, an optional step may be performed to generate programming code for 3D printing the intermediate material at the designated feature location. The intermediate material may be applied to ensure bonding of the first material to the second material. The features to which the intermediate material is applied may be selected by an operator. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device. The programming code for 3D printing of the intermediate material may be automatically generated from the feature pattern design data.

[0086] When the intermediate material is applied, an optional step of 3D printing the intermediate material at the specified feature location may occur at block 650. Based on the programming code generated from the feature pattern design data and the selected features, the intermediate material may be 3D printed onto the feature at the identified location.

[0087] An optional sintering step may be performed when applying the intermediate material at block 655. The sintering step may be performed to fuse the intermediate material to the first material, thereby increasing the strength and structural integrity of the material. Sintering may occur when the intermediate material is printed onto the identified features, for example, using a laser sintering process. Alternatively or additionally, sintering may be accomplished by heat treating the plate segments.

[0088] At block 660, programming code may be generated for 3D printing of a second material at the specified feature locations. The second material may be a more wear resistant material that is added to the features identified in the feature pattern. The features to which the intermediate material is applied may be selected by an operator. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device. The programming code for 3D printing of the second material may be automatically generated from the feature pattern design data and the selected features.

[0089] At block 665, a process of 3D printing a second material at the specified feature location may be performed. Based on the programming code generated from the feature pattern design data and the selected feature, a second material may be 3D printed onto the feature at the identified location. It should be understood that additive machining processes may be performed for the addition of more than one second material.

[0090] At block 670, an optional sintering step may be performed. The sintering step may be performed to fuse the second material to the first material (or intermediate material, if used), thereby increasing the strength and structural integrity of the material. Sintering may be performed as the second material is printed onto the identified features, for example, using a laser sintering process. Alternatively or additionally, sintering may be achieved by heat treating the plate segments. Optionally, a flattening step may be performed on the plate segments.

[0091] The specific steps illustrated in FIG. 6 provide a specific method 600 of additive machining of a plate segment according to an embodiment of the present disclosure. Other sequences of steps may be performed according to alternative embodiments. For example, alternative embodiments of the present disclosure may perform the steps outlined above in a different order. Additionally, the individual steps illustrated in FIG. 6 may include multiple sub-steps that may be performed in various sequences appropriate to the individual step. Additionally, additional steps may be added or removed depending on the particular application.

[0092] FIG. 7 is a flow chart illustrating an example of a method 700 for additive machining of a plate segment having a partial feature pattern, according to various aspects of the disclosure. Referring to FIG. 7, in block 710, a plate segment having a partial feature pattern may be obtained. The plate segment may be, for example, but not limited to, a refiner plate segment, a disperser plate segment, a flinger plate segment, or other plate segment. The partial feature pattern may include, but is not limited to, bars, grooves, dams, channels, or other features. The plate segment may be manufactured using a casting process or other process. The partial feature pattern may be a feature pattern having features with heights determined from a plate segment substrate. The height of the partial feature pattern may be less than the designed height of the features. In some cases, the features of the feature pattern may be dimensioned such that the features are wider at the top surface than at the base of the features.

[0093] After a plate segment having a partial feature pattern is obtained, the locations of features within the feature pattern may be determined by optical scanning (block 720) or by obtaining design programming code for the feature pattern of the plate segment (block 740).

[0094] At block 720, the location of features on the feature pattern may be determined by optical scanning. The plate segment may be scanned to determine the location of features within the feature pattern. The plate segment may be scanned, for example, but not limited to, by a 3D laser scanning device or other optical scanning device, an acoustic based scanning device, a radar based scanning device, etc. The scanning process may identify the perimeter of the plate segment and generate a three-dimensional map that defines the location and dimensions of the features of the feature pattern relative to the perimeter of the plate segment. Thus, no specific alignment of the plate segment is required.

[0095] At block 730, programming code for 3D printing of the feature pattern may be generated. The programming code may be generated from the optical scan data of the feature pattern. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device. Programming code for 3D printing of the intermediate material may be automatically generated from the 3D printing data of the feature pattern.

[0096] Alternatively, the location of the features on the feature pattern may be determined by obtaining design programming code for the feature pattern in block 740. The plate segment design programming code may include design data for the plate segment substrate and the feature pattern of the plate segment.

[0097] At block 750, programming code for 3D printing of the feature pattern may be generated. The programming code may be generated from the design data of the feature pattern. The generated programming code may be code for operating a computer numerically controlled (CNC) 3D printing device. Programming code for 3D printing of the intermediate material may be automatically generated from the design data of the feature pattern.

[0098] At block 760, a plate segment having a partial feature pattern may be placed on a 3D printing apparatus. Accurate placement of the plate segment may be achieved using locations of selected features of the feature pattern based on design data of the feature pattern.

[0099] A process of 3D printing the feature pattern on the plate segment having the partial feature pattern may be performed at block 770. The feature pattern may be 3D printed based on programming code generated from the optical scan or plate segment design data.

[0100] At block 780, it may be determined whether another material is to be 3D printed. For example, it may be determined whether a subsequent material having different properties, such as, but not limited to, wear resistance or other properties, may be 3D printed. In response to determining (780-Y) that a subsequent material is to be 3D printed, the method may continue at block 720 or block 740 with determining the location of features of the feature pattern.

[0101] In response to a determination (780-N) that the subsequent material will not be 3D printed, the method may end.

[0102] It should be understood that when more than one material is 3D printed, the location of the printed feature pattern may be determined by optical scanning or design data, or a combination of optical scanning and design data.

[0103] The specific steps illustrated in FIG. 7 provide a specific method 700 of additive machining of a plate segment having a partial feature pattern according to an embodiment of the present disclosure. Other sequences of steps may be performed according to alternative embodiments. For example, alternative embodiments of the present disclosure may perform the steps outlined above in a different order. Additionally, the individual steps illustrated in FIG. 7 may include multiple sub-steps that may be performed in various sequences as appropriate for the individual step. Additionally, additional steps may be added or removed depending on the particular application.

[0104] Although the above method is described as being applied to refiner plate segments, the method of the present disclosure may be applied to other types of plate segments, such as, but not limited to, disperser plate segments, flinger plate segments, etc., as well as complete disk-type refiner plates, disperser plates, flinger plates, etc., without departing from the scope of the present disclosure. Additionally, the method of the present disclosure may be applied to flat, conical, and cylindrical plate segments, as well as integrally molded circular plates, without departing from the scope of the present disclosure.

[0105] The examples and embodiments described herein are for illustrative purposes only. Various modifications and changes will be apparent to those skilled in the art in light of them. These are intended to be included within the spirit and scope of this application and the appended claims.

Claims

1. 1. A method of additive machining of a refiner plate segment having a feature pattern, comprising: manufacturing the refiner plate segment having a partial feature pattern from a first material; performing a first optical scan of the refiner plate segment to identify locations of features of the partial feature pattern; automatically generating a first code from data obtained from the first optical scan for three-dimensional (3D) printing of a second material at a first designated location of the partial feature pattern; 3D printing the second material at the first designated location; and The method comprising:

2. The method of claim 1 , wherein the second material has a hardness greater than a hardness of the first material.

3. The method of claim 1 , further comprising sintering the second material by heating the refiner plate segment after the 3D printing of the second material.

4. and after manufacturing the refiner plate segment having the partial feature pattern, performing a planarization process to obtain a flat surface on the top surface of the features of the partial feature pattern. The method of claim 1 further comprising:

5. placing the refiner plate segment in a predetermined orientation in a three-dimensional (3D) printing device; obtaining a second pre-programmed code for three-dimensional (3D) printing of a third material at a second designated location of the partial feature pattern; 3D printing the third material at the second designated location using the second pre-programmed code. The method of claim 1 further comprising:

6. placing the refiner plate segment in a three-dimensional (3D) printing device; performing a second optical scan of the refiner plate segment to identify the locations of the features of the partial feature pattern; automatically generating a second code from data obtained from the second optical scan for three-dimensional (3D) printing of a third material at a second designated location of the partial feature pattern; 3D printing the third material at the second designated location; and The method of claim 1 further comprising:

7. three-dimensionally (3D) printing two or more additional materials at the first specified locations based on the first code for 3D printing; The method of claim 1 further comprising:

8. The method of claim 1 , wherein the refiner plate segment is a planar refiner plate segment, a cylindrical refiner plate segment, a conical refiner plate segment, or a single piece roundel.

9. 1. A method of additive machining of a refiner plate segment having a partial feature pattern, comprising: manufacturing the refiner plate segment having a partial feature pattern from a first material based on design data for the refiner plate segment; placing the refiner plate segment in a 3D printer at a known position and orientation; 3D printing to complete features on predetermined features in the partial feature pattern; and program code for 3D printing is provided from design data of the refiner plate segment. The method.

10. The method of claim 9 , wherein placing the refiner plate segment in the known position and orientation is accomplished via a fixture.

11. The method of claim 9 , wherein the known positions and orientations of the plate segments are determined by performing a scan of the refiner plate segments.

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