Method and system for secure connection in layer segments of cut layer add-on components

Abstract

To provide methods and systems for secure connections in individual layer segments connected to each other from one end to the other end.SOLUTION: A method of manufacturing a part with a plurality of cut segments includes receiving a sheet of material with a machining apparatus, removing material with the machining apparatus to form a plurality of segments in the sheet of material, and forming complementary shapes in ends of two or more segments of the plurality of segments. The method further includes forming slots in the two or more segments, aligning the slots in the two or more segments to form a cavity, and inserting a connecting device to fill the cavity.SELECTED DRAWING: Figure 2A

Description

Technical Field

[0001] Technical Field Aspects of the present disclosure relate to systems and methods for fabricating components. In some cases, aspects of the present disclosure relate to systems and methods for fabricating components (such as patterns, molds, and similar products) using techniques or processes similar to 3D printing processes involving layer formation. These techniques or processes can, in at least some embodiments, enable the manufacture of lower-cost molds or tools without using a 3D printer.

Background Art

[0002] Background Generally, additive manufacturing techniques and processes involve the deposition of one or more materials to create net shape or near-net shape (NNS) objects, in contrast to subtractive manufacturing methods. "Additive manufacturing" is an industry standard term (ASTM F2792), but additive manufacturing encompasses manufacturing techniques and prototyping techniques known by various names, such as freeform fabrication, 3D printing, rapid prototyping fabrication / tooling, and the like.

[0003] Some additive manufacturing techniques use large 3D printers that can manufacture very large parts, molds, patterns, etc. These parts can be made, for example, from fiber-reinforced thermoplastic materials. One method of manufacturing these parts utilizes a polymer extruder to produce beads of molten thermoplastic material, and these beads of material are added in sequence so that the part is manufactured one layer at a time. These layers can be modified and / or flattened into wider beads during the additive manufacturing process using devices such as a pressure plate, rotor, etc. Using these methods, which are sometimes referred to as 3D printing, the part is slightly larger than desired. The part is machined to its final size and shape after cooling and curing. The resulting part is generally a shell having a specific thickness and the desired approximate size and shape.

[0004] Another type of additive manufacturing can be called "cut-layer" additive manufacturing. In some examples of cut-layer additive manufacturing, pieces can be cut from a porous material, stacked on top of each other, and bonded together to create a part. In some cases, this part can be hollow and composed of individual elements that are narrow beads that, when stacked together, form a shell or wall around the outline of the desired part. In some techniques, the shell or wall is made of a porous material into which a catalytic thermosetting liquid is injected. This liquid is designed to harden and create a rigid composite part reinforced with the porous material.

[0005] However, there are cases where it is desirable to manufacture parts from non-porous materials such as metals (e.g., aluminum). Examples of potential applications for such parts include industrial molds and tools used in plastic molding processes such as thermoforming, blow molding, rotational molding, and reaction injection molding. Generally, aluminum molds for applications such as compression molds and injection molds are not suitable for long-term production, but if aluminum molds are reasonably cost-effective and can be produced within a reasonable timeframe, they may be desirable for prototype fabrication and short-term sample production.

[0006] One reason why aluminum and other materials, despite possessing desirable properties, are not used for at least some applications such as molds and tools is that these relatively large parts require large blocks of material, and removing the excess material (e.g., through machining) to create the desired cavity shape for the mold is time-consuming. This is especially true for large, deep parts where more than half of the material needs to be removed to obtain the desired final part geometry.

[0007] Some components, including tools, could benefit from structures with internal channels that allow heated or cooled liquids to circulate to control the tool's temperature during operation. However, machining these channels into a solid block of material requires considerable time and specialized equipment, further increasing construction time and cost. Furthermore, in some cases, machining these channels into the solid block from the outside may prevent their placement in specific areas of the mold. This can make it impractical or impossible to create channels in certain locations on parts produced using conventional additive manufacturing techniques.

[0008] Cut-layer additive manufacturing allows the use of sheet-like materials, which typically result in a lower cost per pound of the final product compared to parts formed from one or more large blocks of the same material. Cut-layer manufacturing may offer advantages because it requires less material to be machined to produce the final product. Additionally, cut-layer manufacturing can provide the ability to form heating and / or cooling channels in the cut sheet, which are not easily machined in solid block-like materials.

[0009] In certain applications, such as molds for plastic processing, it is desirable that the surface of a cut-layer structure, after assembly, resembles a solid piece of material (such as metal) rather than a structure assembled from a series of individual parts. To facilitate the assembly of parts in these applications, not only the individual layer segments but also the layers formed by these segments must be securely connected. [Overview of the Initiative]

[0010] overview Aspects of this disclosure relate, in particular, to methods and apparatus for manufacturing components by lamination technology. Each aspect disclosed herein may include one or more features described in relation to any of the other aspects disclosed. Objects of this disclosure include, for example, methods for achieving tight connections between individual layer segments that are connected to each other from end to end.

[0011] A method performed in accordance with this disclosure begins, for example, with cutting the ends of interlocking layer segments. These ends can be cut into a V-shape or other shape so that the two interlocking ends do not slip relative to each other (e.g., left to right) when tightly pulled. Following the formation of the formed ends, holes can be drilled or milled into each of the interlocking ends of the layer segments. Slots can then be milled from the holes to each end of the layer segments so that when the ends of the two layer segments are fitted end-to-end, the pairs of slots align with each other. This allows for the formation of a non-slip connection.

[0012] To facilitate this connection, a connector can be used that has a shape (e.g., dumbbell-shaped) that matches the shape of the two through-holes or blind holes. The connector may include a portion shaped to match the slot connecting the two holes. The connector can taper from a larger upper profile to a smaller lower profile, in which case the lower portion fits easily (e.g., with a gap) into the dumbbell-shaped holes at the ends of the two layer segments, while the upper portion of the connector forms an interference fit. Thus, when the connector is pushed into the holes, the two layer segments join together tightly, and the two ends are held together with considerable pressure.

[0013] In one embodiment, a method for manufacturing a part having multiple cut segments may include receiving a sheet of material in a machining apparatus, removing material in the machining apparatus to form multiple segments in the sheet of material, and forming complementary shapes at the ends of two or more of the multiple segments. The method may further include forming slots in two or more segments, aligning the slots of two or more segments to form a cavity, and inserting a connecting device to fill the cavity.

[0014] In another embodiment, a method for manufacturing a part having multiple cut segments may include receiving a sheet of material in a machining apparatus, removing the material in the machining apparatus to form multiple segments in the sheet of material, and further forming a concave end extending from the face of the first of two segments. This method may further include forming a protruding end having a shape complementary to the shape of the concave end, inserting the protruding end into the concave end, and fixing the protruding end to the concave end.

[0015] In yet another embodiment, a system for manufacturing a part having multiple segments may include a machining apparatus configured to receive a sheet of material and a controller configured to generate commands for controlling the machining apparatus. The controller can be programmed to cause the machining apparatus to remove material to form multiple segments from the sheet of material, to cause the machining apparatus to form complementary shapes at the ends of two or more of the multiple segments, and to cause the machining apparatus to form slots in two or more segments.

[0016] The accompanying drawings incorporated herein and constituting part thereof illustrate exemplary aspects of this disclosure and, together with the description, help to illustrate the principles of this disclosure. [Brief explanation of the drawing]

[0017] [Figure 1] This is a perspective view of an exemplary material removal device (e.g., a CNC machine) that is operable to locate layers of sheet material according to one aspect of the present disclosure. [Figure 2A] This is an enlarged perspective view of an exemplary layer segment having V-shaped tapered ends connected to one another according to an aspect of the present disclosure, with each tapered end having a cavity formed by holes and slots. [Figure 2B] This is an enlarged perspective view of an exemplary layer segment having V-shaped tapered ends connected to one another according to an aspect of the present disclosure, with each tapered end having a cavity formed by holes and slots. [Figure 3] This is a perspective view of an exemplary connector, which has a bottom smaller than the cavity housing the connector and an upper the same size as or slightly larger than the cavity. [Figure 4] This is a perspective view of an exemplary connector that is inserted into the cavity between two layer segments and firmly pulls the layer segments together. [Figure 5A] This is an enlarged perspective view of an exemplary layer segment, each with a rounded end and a straight end. [Figure 5B] This is an enlarged perspective view of an exemplary layer segment, each with a rounded end and a straight end. [Figure 6A] This is an enlarged perspective view of different exemplary cavities within different layer segments, which can be used with compatible connectors to achieve tight connections between ends. [Figure 6B] This is an enlarged perspective view of different exemplary cavities within different layer segments, which can be used with compatible connectors to achieve tight connections between ends. [Modes for carrying out the invention]

[0018] This disclosure relates, in particular, to methods and systems for manufacturing different types of components by layering techniques. Specifically, the methods and systems described herein can be end-to-end connected to manufacture layers and enable tight connections between individual layer segments.

[0019] In contrast to some manufacturing methods that involve machining the material of a solid block, aspects of the present disclosure include assembling a part, such as a mold blank, by stacking layer segments cut and separated from a sheet of material. The material can be a solid and non-porous material such as aluminum. In some aspects, a layered mold blank is produced that substantially matches the desired size and shape of the final mold. This layered mold blank is then machined to the final size and shape. These procedures can be constructed in layers and produce parts with a structure similar to conventional additive manufacturing parts.

[0020] As shown in FIG. 1, a cutting machine 11, such as a CNC router, can be used to cut layers from a material sheet 12. The controller 60 may be incorporated into the machine 11 as described herein and / or be part of a system for manufacturing the part. The controller 60 can be configured to generate commands for the machine 11 to remove material from the sheet 12 to form a plurality of layers, as also described herein. The machine 11 is configured to receive one or more sheets of material 12, and the one or more sheets 12 provide material for forming segments that form a complete part when assembled.

[0021] These layers can be assembled together to form a part, in contrast to a process where layers are applied to each other during a printing process. The individual layers can be fixed in various ways, such as by covering the assembled layers with plastic (such as resin).

[0022] One or more layers of the part can include a plurality of individual layer segments. For example, the first layer may be formed by segments 13, 14, 15, and 16, the second layer may be formed by segments 17, 18, 19, and 20, and the third layer may be formed by segments 21, 22, 23, and 24.

[0023] In some embodiments, it can be difficult to secure a particular layer segment in a way that allows plastic to be formed on top of the layer. Referring to Figure 2A, an exemplary approach to address these challenges involves machining a corresponding shape, such as a matching taper, at the ends of opposing segments.

[0024] In the example shown in Figure 2A, the layer segment 14 may be machined in the cutting machine 11 to form complementary shapes, including complementary surfaces such as surfaces 38 and 40. These complementary shapes may include a "V" tapered shape having a recessed central portion extending into the surface (e.g., the side edge) of the layer segment 14 and protruding side edges of the surface of the segment 14.

[0025] By performing a machining process on the layer segment 15 in machine 11, a mating or complementary "V" taper shape can be formed, resulting in a protruding central portion and recessed side ends. The ends of segments 14 and 15 may be shaped so that when connected, the ends of segments 14 and 15 lock together, as shown in Figure 2B. When in contact as shown in Figure 2B, segments 14 and 15 are restricted from moving left and right relative to each other. Figures 2A and 2B show exemplary tapers that form an angle (for example, an angle of about 90 degrees measured from the two surfaces that form the "V" legs), but other complementary shapes are also possible. Also, as should be understood, when a "V" taper shape is used, the "V" taper shown in Figure 2A is just one example. Other examples of "V" tapers include slight "V" tapers formed by a larger angle (such as an obtuse angle formed by the "V" legs), or deeper "V" tapers formed by a narrower angle (such as an acute angle formed by the "V" legs).

[0026] In at least some embodiments, the first hole 25 and the second hole 26 can be drilled or machined at the ends of the layer segments 14 and 15. This can be done by removing material from above, for example using a machine 11, at a distance from where the layer segments connect.

[0027] In addition to the holes 25 and 26, which may be through holes or blind holes, one or more slots may be formed in the segments 14 and 15. For example, a first slot 27 may be formed at the end of segment 14, and a second slot 28 may be formed at the end of segment 15. The widths of the slots 27 and 28 may be smaller than the diameters of the holes 25 and 26. In some embodiments, the widths of the slots 27 and 28 may be the same or approximately the same.

[0028] Slots 27 and 28 can be machined to extend from the ends of holes 25 and 26 to the ends of each segment 14 or 15. Thus, when the two layer segments 14 and 15 are positioned end-to-end and fitted together for assembly, as shown in Figure 2B, slots 27 and 28 form a portion that forms a single continuous slot in the cavity 29 when aligned with each other. The cavity 29 may include this continuous slot and holes 25 and 26 machined at the ends of the layer segments 14 and 15. In the example shown in Figure 2B, the cavity 29 has a dumbbell shape formed by holes 25 and 26 that are wider than the continuous slot formed by slots 27 and 28.

[0029] As shown in Figure 3, a connector 30 can be formed for use with segments 14 and 15. In some configurations, the connector 30 can be made from the same material as the layer segments 14 and 15, such as aluminum or other metals. However, if necessary, the connector 30 may be formed from one or more different materials.

[0030] Referring to Figure 3, the connector 30 may have the same general shape as the holes 25 and 26 and slots 27 and 28 formed between the layer segments 14 and 15 when the layer segments 14 and 15 are fitted together for assembly. As shown in the illustrated example, the connector 30 may have a barbell shape when viewed from above, with two generally circular sides 50 connected by a bridge 52 extending in a straight line.

[0031] In at least some embodiments, the connecting device 30 may have a tapered shape. This tapering may be formed between the front and rear ends of the device 30. As shown in Figure 3, the device 30 may be tapered such that the rear end 31 is smaller and the front end 32 is larger, defining at least one wall that tapers from the larger end 32 toward the smaller end 31. Each end 31 and 32 may include a circular side portion 50 and a bridge 52 connecting these sides. The side portion 50 and bridge 52 of the rear end 31 of the smaller end may define a smaller circumference than the corresponding circumference defined by the side portion 50 and bridge 52 of the front end 32.

[0032] In some embodiments, the outer circumference of the connector 30 may be slightly smaller than the machined cavity 29 (Figure 2) between the mating layer segments at the bottom end 31. The enlarged end 32 of the connector 30 may have an outer circumference that is approximately the same size as, or slightly larger than, the machined cavity 29. This smaller outer circumference of the connector 30 may facilitate insertion of the connector 30 into the cavity 29. The side portion 50 of the connector 30 may be larger than one or both (e.g., diameter) of the holes 25 and 26 at the enlarged end 32. Furthermore, or alternatively, the bridge 52 of the enlarged end 32 may be larger than one or both (e.g., width) of the slots 27 and 28.

[0033] For example, as shown in Figure 4, the connector 30 can be pushed down with sufficient force by a human or mechanical device (e.g., an assembly robot or other automated assembly system) so that the connector 30 fits completely into the two layer segments 14 and 15 and securely fastens the segments 14 and 15. In some embodiments, the size of the enlarged end 32 may result in an interferential fit between the cavity 29 and the connector 30. In these embodiments, a considerable downward force may be used to insert the connector 30. Advantageously, a slight taper on the connector 30 from end 32 to end 31 causes the layer segments 14 and 15 to be pulled together when the connector is inserted into the cavity 29. This pulling force may be sufficient to eliminate any gaps that may exist between segments 14 and 15.

[0034] Exemplary embodiments including the connector 30 and cavity 29 have been described above and are shown in Figure 2A-4, but variations of these embodiments are also possible. For example, instead of providing a taper to the connector 30, the taper can be machined into the cavity 29 of the layer segments 14 and 15 so that the lower end and enlarged upper end are directly formed in the segments 14 and 15. Thus, if the cavity 29 is observed along the direction in which the connector 30 is inserted into the cavity 29, a taper may be present. In these embodiments, a straight-walled connector 30 (i.e., a connector 30 without a taper between ends 31 and 32) can be used.

[0035] Furthermore, while Figures 2A, 2B, and 4 show embodiments in which the machine 11 forms a "V"-shaped end, the ends of the layer segments 14 and 15 can also be formed using shapes other than the "V" shape. Other shapes are also possible, including the shapes shown in Figures 5A, 5B, 6A, and 6B.

[0036] As shown in Figure 5A, in at least some embodiments, rounded ends may be used. These ends may include protruding ends 44 and recessed ends 42. The protruding end 44 may include a central projection (the center of which is measured, for example, along the width of segment 19) facing the recessed end 42. The recessed end 42 has a recessed central portion (measured along the width of segment 17) and protruding lateral ends. In some embodiments, slots 27 and 28 may be formed at the deepest part of the recess and the end of the projection, respectively.

[0037] Some aspects of the present disclosure include using the device 30 without forming geometrically shaped joints at the ends of two or more segments. Rather, as shown in Figure 5B, segments 21 and 23 may have straight ends with flat surfaces 46 and 48, or other shapes without mating recesses and protrusions. The flat surfaces 46 and 48 can butt into contact (e.g., form a butt joint) when the connecting device 30 is inserted into the holes 25 and 26 and slots 27 and 28, preventing the formation of a gap between ends 46 and 48.

[0038] In some embodiments, the cavity 29 may be modified, although this involves modifying the protruding and recessed ends of the segments (e.g., by forming recessed ends 42 and protruding ends 44). For example, as shown in Figures 6A and 6B, the holes in the cavity 29 may be formed in different shapes. As shown in Figure 6A, the holes 33 and 34 may be formed in an ellipse rather than substantially circular. These ellipses may be used with a connector 30 having rounded ends of a similar shape (e.g., elliptical). As described above, the connector 30 may have a tapered shape, but instead, the holes 33 and 34 and / or slots 27 and 28 may have a tapered shape.

[0039] In another example shown in Figure 6B, the holes may be formed as slots 35 and 36 in addition to slots 27 and 28. Slots 35 and 36 may be through holes or blind holes intersecting slots 27 and 28, respectively. Slots 35 and 36 may have rounded ends to facilitate the insertion of the connector 30 and to avoid sharp edges or ends that may interfere with the insertion of the device 30. The openings formed by slots 35 and 36, as well as holes 33 and 34, can be used with connectors 30 of a matching shape. A suitable device 30 may have a tapered shape, and / or slots 35 and 36 and slots 27 and 28 may have a tapered shape to facilitate interference mating.

[0040] Each of the embodiments described above may include a method for manufacturing a part from multiple cut segments. As an example, the method may include receiving a sheet of material 12 in a machining apparatus or cutting machine 11. This method may include removing material from the sheet of material 12 to form layered segments such as segments 13-24 shown in Figure 1. By further removing material in the machine 11, two or more segments 13-24 can be formed with complementary shapes at each end of the segments (for example, as shown in Figures 2A, 2B, and 4-6B). By removing additional material from each segment with complementary shapes (for example, in the machine 11), slots 27 and 28 can be formed.

[0041] A method for manufacturing parts from cut segments may also include aligning slots by arranging a pair of complementary shapes in contact with each other. This contact forms a cavity 29, which has a continuous shape defined by holes 25 and 26 and slots 27 and 28. A connecting device 30 can be inserted into the cavity 29 to fill it and prevent separation of the connected segments.

[0042] In some embodiments, the controller 60 may be configured to generate commands that enable the cutting machine 11 to perform at least a portion of the above method. For example, the controller 60 may be programmed to generate commands that cause a machining device, such as the machine 11, to remove material from the sheet 12 to form the segments 13-24 and the connecting device 30.

[0043] From the detailed description above, it will be apparent that the Method and System are subject to numerous changes, adaptations, and modifications that fall within the realm of those with ordinary skill in the art relating to the foregoing disclosure. However, all such changes that do not deviate from the spirit of the Disclosure are intended to be considered to be within the scope limited by the appended claims. [Explanation of Symbols]

[0044] 13-24 segments 27 slots 28 slots 29 Cavity 30 Connection device 42 Recessed end 44 Projecting end 52 Bridge

Claims

1. A method for manufacturing a part having multiple cut segments, Receiving the material sheet from the machining equipment, The process involves removing material with the aforementioned machining apparatus to form multiple segments on the sheet of material, To form complementary shapes at the ends of two or more segments among the aforementioned plurality of segments, Forming slots in the two or more segments, Aligning the slots of the two or more segments to form a cavity, A method comprising inserting a connecting device to fill the cavity.

2. The method according to claim 1, wherein the connecting device has a side portion that is wider than the width of the central portion of the connecting device.

3. The method according to claim 1, wherein the connecting device includes a bridge connecting a pair of enlarged sides.

4. The method according to claim 1, wherein the connecting device has a wall that tapers from an enlarged end to an end smaller than the enlarged end.

5. The method according to claim 1, wherein the slot is formed at the ends of the two or more segments that form a butt joint.

6. The method according to claim 1, further comprising forming through holes in the two or more segments, wherein the through holes are directly connected to their respective slots.

7. The method according to claim 6, wherein the through holes are formed at each end of the slot.

8. The method according to claim 6, wherein the through hole has a generally circular or elliptical shape.

9. A method for manufacturing a part having multiple cut segments, Receiving the material sheet from the machining equipment, The process involves removing material with the aforementioned machining apparatus to form multiple segments on the sheet of material, To form a recessed end extending to the surface of the first of the segments, To form a protruding end having a shape complementary to the shape of the recessed end, Inserting the protruding end into the recessed end, A method comprising fixing the protruding end to the recessed end.

10. The method according to claim 9, wherein the concave end and the protruding end form complementary tapered shapes.

11. The method according to claim 9, wherein the concave end and the protruding end form a complementary "V" shape.

12. A system for manufacturing a component having multiple segments, A machining apparatus configured to receive a sheet of material, The system includes a controller configured to generate commands for controlling the aforementioned machining apparatus, The aforementioned controller, The machining apparatus removes material to form multiple segments from the sheet of material, The machining apparatus is used to form complementary shapes on the ends of two or more segments among the plurality of segments, The machining apparatus is used to form slots in the two or more segments, A system that is programmed to perform a certain action.

13. The system according to claim 12, wherein the controller is further programmed to form enlarged portions at one or both ends of the slots of the two or more segments.

14. The system according to claim 12, wherein the controller is further programmed to cause the machining apparatus to form a concave end on one of the two or more segments and a protruding end on another of the two or more segments, the concave end and the protruding end forming the complementary shape.

15. The system according to claim 14, wherein the controller is further programmed to cause the machining apparatus to perform the action of forming the protruding end into a rounded shape.

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