Method for obtaining a hybrid cutlery piece and respective cutlery piece

Abstract

The present description relates to a method for obtaining a hybrid metal cutlery piece by stamping and additive manufacturing, wherein the cutlery piece comprises a first part (1) previously obtained by cutting and stamping and a second part (2) obtained by additive manufacturing, wherein the first part (1) is a ladle, a blade, or tines of the cutlery piece, and wherein the second part (2) is a handle of the cutlery piece, said parts being joined on a joining surface. It also relates to said cutlery piece.

Description

DESCRIPTION METHOD OF OBTAINING A HYBRID CUTLERY PIECE AND THE CORRESPONDING CUTLERY PIECE Technical Mastery

[0001] This description relates to a method for producing a cutlery piece and its component. It specifically refers to a method for producing a hybrid metal cutlery piece by stamping and additive manufacturing, as well as the corresponding component. BACKGROUND

[0002] Additive manufacturing has been used across a wide range of industries. Cutlery products made using additive manufacturing have already been developed, but the main distinction lies in the fact that all of these products were designed entirely using this method.

[0003] Patent document JP6746308B2 describes technologies that can be used to achieve this union in a hybrid design, precisely highlighting the most suitable technologies for this purpose. However, the document does not address the development of specific products, much less products intended for the cutlery industry.

[0004] Patent document W02014011262 describes a hybrid core used in the manufacture of turbine engine parts. The hybrid core is characterized by the combination of two distinct parts: a first part made of non-refractory metal and a second part made of refractory or non-refractory metal. The additive manufacturing process is used to produce at least one of the parts, either the first or the second.

[0005] Patent document GB2620652 describes a method for post-processing a part manufactured through additive manufacturing, such as 3D printing. The method involves providing the additively manufactured part, providing A fluid for post-processing the part is used to improve the surface finish. The fluid contains at least one carboxylic ester, the fluid is heated, and the heated fluid is applied to the surface of the part. While the newly created solution, post-processing is entirely performed using conventional cutlery methods, including polishing and applying the corresponding finishes to the parts, such as high gloss, gold, black titanium, and others.

[0006] Patent document US20230141426 describes a cutting tool having a blade comprising a base portion and a tip portion arranged along an edge of the base portion, wherein: the base portion comprises a hollow body formed by sintering a first powder constituent material; the tip portion comprises a solid body formed by sintering a second powder constituent material; and a reinforcing wall is provided within the hollow body in at least a tip portion of the cutting tool of the base portion.

[0007] Chen, L. (2017) "A cutlery set for stroke", Victoria University of Wellington, School of Design, describes the production of cutlery by additive manufacturing. In this article, the part is obtained entirely by additive manufacturing, more specifically by direct metal laser sintering (DMLS).

[0008] These facts are described in order to illustrate the technical problem solved by the achievements of this document. GENERAL DESCRIPTION

[0009] There is currently a need for innovation in the cutlery industry, using additive manufacturing to complement traditional production methods.

[0010] This description arises as a response to the continuous growth of the cutlery sector and the constant evolution in production methods through new technologies.

[0011] The proposed solution consists of developing hybrid cutlery pieces, in which a first part is produced by conventional methods and a second part is produced through additive manufacturing. This approach allows combining the knowledge and established processes of the cutlery industry with the advantages offered by additive manufacturing, such as the freedom to design diverse models, the simplification of labor and the reduction in the number of steps required to create handles and tops of cutlery, which can be a shell, a blade or teeth.

[0012] The synergistic combination of these two distinct production processes allows for the advancement of the cutlery industry without hindering established processes. The decision to incorporate additive manufacturing is based on the various advantages this approach provides, such as the freedom to design highly diverse models, the reduction in the number of production steps required, and the ability to produce multiple handles simultaneously.

[0013] In one embodiment, the integration of additive manufacturing of a second part of the cutlery piece with the traditional methods of producing a first part of the cutlery piece, allows the creation of cutlery pieces of high diversity and fully exploits the potential of this technology to meet the specific requirements of the cutlery industry.

[0014] In one embodiment, two combined methods are presented for producing a cutlery piece. The first involves creating a second part of the cutlery piece using powder bed fusion technology, specifically the direct metal laser sintering (DMLS) production process. The first part is obtained using traditional cutlery industry processes. This specific DMLS process allows the second part to be welded simultaneously with the first part, meaning that post-processing is required when the piece is finished, as it will be in its raw state.

[0015] In one embodiment, the traditional method involves the following steps: the first part of the cutlery piece is manufactured from a bar or sheet of steel, typically AISI 420 steel for the handle and AISI 304 for knife blades, spoon bowls, or fork tines, but this can vary. This step involves cutting between punches and dies, and stamping between a mold. The resulting part is then sanded and polished, and in some cases, sharpening is necessary.

[0016] In one embodiment, the first part of the cutlery piece comprises a stop from which the second part is produced. The stop acts as a support for the beginning of the construction of the second part, as it provides a solid base from which the fabrication of the second part of the piece can begin with precision.

[0017] In one embodiment, the first part has a stop so that the second part can then have support to begin production.

[0018] This description also refers to a support, also called a JIG, which is intended to support the part obtained by the traditional method in a vertical orientation, ensuring that they are properly secured and prevent any deviation during production. Thus, the support, or JIG, is divided into two parts and produced from a steel block cut to specific dimensions. Subsequently, on a CNC machine, the block is measured and ground according to the design specifications, using different cutters at various stages of the process. Once the JIG is ready, the first part of the part is placed inside the support, and any potential tenons present in the first part are cut.

[0019] The precise alignment between the start of the construction of the second part of the piece and the stop of the first part of the cutlery piece obtained by the traditional method is possible due to the three-dimensional modeling of the JIG, which guides the machine for the exact production of the second part of the piece.

[0020] The use of this support has multiple functions that, in addition to positioning the first part of the cutlery piece in a vertical orientation and ensuring its fixation, also facilitates alignment between the start of the construction of the second part in additive manufacturing and the first part.

[0021] For best results, the support was modeled with precise measurements based on existing parts, simplifying the alignment process. That is, the support has cavities inside to receive and support the first part of the cutlery piece obtained using the traditional method. The dimensions of the cavities are precise, avoiding any gaps that may arise. Any misalignment during production between the first part and the second part of the cutlery piece can be corrected in post-processing in the cutlery, using sanding and polishing techniques on the piece.

[0022] In one embodiment, the support is made of steel.

[0023] For best results, the first part of the part should always be used in production in its raw state, since the second part also leaves the machine in this state and requires the same post-processing.

[0024] For best results, the stop has a flat surface to ensure a precise fit. Flat means it should be perpendicular to the laser beam used for additive manufacturing.

[0025] For best results, the stop should be (i) parallel to the building base and, as such, (ii) perpendicular to the laser beam, presenting a flat surface.

[0026] In one embodiment, the second part of the cutlery piece is made of stainless steel, preferably Uddeholm Corrax, specially developed for additive manufacturing, ensuring corrosion resistance and high hardness.

[0027] After the second part is produced, the support is removed and post-processing can then be carried out, ensuring that the final cutlery piece meets the desired quality standards.

[0028] In this way, the problem of joining the part of the part produced in a traditional way to the second part manufactured by additive manufacturing is solved through the development of a precise JIG, the controlled production of the parts and post-processing to guarantee the final quality of the product.

[0029] Alternatively, in the second option, production is independent of the traditionally produced part of the piece, with the first part produced traditionally and the second part via additive manufacturing. The two parts are joined in traditional production, using a common approach for hollow-handled cutlery. Thus, the difference t is that in this case it is not necessary to carry out the JIG, since the connection between the first and second part of the cutlery piece is made using the traditional method.

[0030] After the second part is produced through additive manufacturing, it is removed in its raw state, ready for joining with the first part of the part. The first and second parts are joined using a butt welding machine, using a technique that promotes coalescence between the two parts across the entire contact area. This process uses heat generated by resistance to electrical current, using the cable's own steel to effectively weld both parts. With the first and second parts joined, post-processing is then performed to enhance the aesthetics and functionality of the final product.

[0031] For best results, the joining occurs through heat generated by resistance to the electric current. This electric current is applied in a controlled manner, promoting fusion and coalescence between the steel of the handle and the head of the cutlery piece. This technique uses the steel of the second part of the piece itself, ensuring an effective and durable weld. Precise control of heat and electric current ensures a robust joint between both parts, providing consistent quality.

[0032] Furthermore, the steel hardness of the second part of the additively manufactured part must be controlled to ensure the values ​​are as similar as possible, ensuring compatibility during the joining process. Therefore, uniform hardness is necessary to ensure the structural integrity and final performance of the product.

[0033] Some of the main advantages are: solving the need for innovation in the cutlery industry by integrating additive manufacturing with traditional production methods to create highly diverse pieces; combining the knowledge and established processes of the cutlery industry with the advantages offered by additive manufacturing, fully exploiting the potential of this technology; providing freedom to design highly diverse models for knife, spoon, or fork handles, allowing for customized and innovative designs; combining different production processes synergistically, reducing the number of steps required to create knives, spoons, or forks, optimizing the time and resources involved in production; offer flexibility in production, allowing the choice between direct joining in additive manufacturing or traditional production, according to the manufacturer's needs and preferences; after production, all parts undergo post-processing processes for final adjustments, ensuring the aesthetic and functional quality of the final product; offer flexibility and control in production, allowing the choice between different methods of joining the handle to the rest of the part, adapting to the needs and demands of the cutlery market.

[0034] The present description relates to a method of obtaining a hybrid metal cutlery piece by stamping [i.e., in which a sheet or rod metal material is shaped between a punch and a die] and by additive manufacturing [i.e., by selectively depositing successive layers of metal material on top of each other], in which the cutlery piece comprises a first part previously obtained by cutting and stamping and a second part obtained by additive manufacturing, in which the first part is a shell, a blade, or teeth of the cutlery piece, and in which the second part is a handle of the cutlery piece, said parts being joined together at a joining surface, in which said method comprises the following steps: providing a support for positioning the first part with the joining surface facing upwards; placing said first part on said support;deposit and sinter a metallic material in successive layers directly on the joining surface to obtain said second part.;

[0035] In one embodiment, the first part comprises a stop on which said joining surface is arranged to receive the second part.

[0036] In one embodiment, the first portion has a longitudinal axis and is disposed with the longitudinal axis in a vertical orientation [the first portion is disposed in a vertical orientation, substantially parallel to the laser, so that a beam from the laser can be applied perpendicular to said stop].

[0037] In one embodiment, the support comprises a first plate and a second plate interlockable, wherein the support comprises at least one cavity formed between said plates and extending from the top of the support to receive and support said first part.

[0038] In one embodiment, the cavity is formed in one or both of said plates, in particular the support comprising fasteners, more in particular bolts, for joining said plates.

[0039] In one embodiment, the cavity of the support is configured so that when the first portion is supported on said support, the stop protrudes from, or is flush with, a top surface of the support.

[0040] In one embodiment, the cavity has the inverse shape of said first part.

[0041] In one embodiment, the support comprises a plurality of cavities for receiving and supporting a plurality of first parts, in particular wherein the plurality of cavities are equidistantly distributed.

[0042] The present description also relates to a method of obtaining a hybrid metal cutlery piece by stamping and additive manufacturing, in which the cutlery piece comprises a first part previously obtained by cutting and stamping and a second part obtained by additive manufacturing, in which the first part is a shell, a blade, or teeth of the cutlery piece, and in which the second part is a handle of the cutlery piece, said parts being joined together at a joining surface, in which said method comprises the following steps: depositing and sintering a metal material in successive layers to obtain said second part; providing said first part; welding said parts together by said joining surface [i.e., welding from English, i.e., joining said parts by heating them to the melting point, applying pressure between them, to create a permanent joint between the parts],

[0043] In one embodiment, the method comprises the additional step of removing excess material from said first part, in particular sanding and / or polishing the first part.

[0044] In one embodiment, the method comprises the prior step of removing a metal pin from said first part, wherein said metal pin is the result of stamping.

[0045] In one embodiment, the deposition and sintering is by direct metal laser sintering (DMLS).

[0046] In one embodiment, the laser is applied perpendicular to said joining surface.

[0047] In one embodiment, the method comprises a prior step of metal stamping of the first part.

[0048] In one embodiment, said joining surface is a planar surface or comprises a plurality of planar surfaces.

[0049] In one embodiment, the metal material is steel, preferably Uddeholm Corrax™.

[0050] The present description also refers to a hybrid metal cutlery piece obtainable by the method described.

[0051] In one embodiment, the hybrid metal cutlery part, stamping and additive manufacturing, comprises: a first metal part previously obtained by cutting and stamping, and a second metal part obtained by additive manufacturing; in which the first part is a shell, a blade, or teeth of the cutlery part; in which the second part is a handle of the cutlery part; in which said parts are joined at respective joining surfaces; and in which the second part was obtained by depositing and sintering a metal material in successive layers directly on the joining surface to obtain said second part.

[0052] In one embodiment, the piece is a fork, a knife, or a spoon. BRIEF DESCRIPTION OF THE FIGURES

[0053] For easier understanding, the figures are attached, which represent preferred embodiments that are not intended to limit the scope of this description.

[0054] Figure 1: Schematic representation of a cutlery piece, namely a knife.

[0055] Figure 2: Schematic representation of a knife in which blade 1 was obtained by the traditional method, handle 2 was obtained by additive manufacturing and stop 3 is visible.

[0056] Figure 3: Schematic representation of a knife blade design.

[0057] Figure 4: Schematic representation of a knife construction.

[0058] Figure 5: Schematic representation of a stop implementation and its alignment.

[0059] Figure 6: Schematic representation of a support implementation.

[0060] Figure 7: Schematic representation of a support construction with the second part extending from it.

[0061] Figure 8: Schematic representation of a model of the support, with the blades visible inside and the cables extending from one end.

[0062] Figure 9: Schematic representation of a support implementation with the cutlery piece.

[0063] Figure 10: Schematic representation of a mold implementation with the cutlery piece. DETAILED DESCRIPTION

[0064] This description concerns a method of obtaining a hybrid metal cutlery piece by stamping [i.e., in which a sheet or rod metal material is shaped between a punch and a die] and by additive manufacturing [i.e., by selective deposition of successive layers of metallic material on top of each other], in which the cutlery piece comprises a first part previously obtained by cutting and stamping and a second part obtained by additive manufacturing, in which the first part is a shell, a blade, or teeth of the cutlery piece, and in which the second part is a handle of the cutlery piece, the said parts being joined together at a joining surface; as well as to the said cutlery piece.

[0065] The following concerns obtaining a knife.

[0066] In one embodiment, a piece of cutlery was obtained in which the first part of the piece is the blade and the second part of the piece is the handle.

[0067] In one embodiment, both the handle and blade of the knife are produced separately, with the handle manufactured using additive manufacturing and the blade produced using one of the traditional methods.

[0068] The main challenge with this solution is ensuring precise alignment between the blade and handle during the manufacturing process, as they are distinct production methods. To address this, one can opt to use the blade in its raw state, thus allowing room for adjustments during post-processing.

[0069] The joint between the handle and the blade is carried out directly on the machine during the additive manufacturing process, using methods such as Direct Metal Laser Sintering (DMLS).

[0070] After production, the knife in its entirety, including the handle and blade, undergoes post-processing for final adjustments and to ensure the aesthetic and functional quality of the final product.

[0071] Alternatively, the cutlery piece can be obtained so that the joint of the part obtained by additive manufacturing is joined during traditional production.

[0072] In this alternative, the production of the blade and handle is also carried out independently, with the blade being manufactured in the traditional way and the handle through additive manufacturing.

[0073] The difference with this alternative is that the union between the blade and the handle occurs during traditional production, using methods common in hollow-handled cutlery, rather than being carried out directly on the machine during the additive manufacturing process.

[0074] The connection between the handle and the blade is made by welding on a butt welding machine, using the handle's own steel to weld the two parts.

[0075] As with the first solution, after joining the parts, the piece undergoes post-processing processes for final refinement and ensuring the quality of the final product.

[0076] A viable alternative is to replace the cable material with polymer, while maintaining the additive manufacturing process.

[0077] Another possibility would be to apply this same process to dies for the production of cutlery, promoting adjustments that would make the process more efficient and refined, reducing the need for labor.

[0078] In one embodiment, Figure 1 represents a knife embodiment in which 1 is the first part, namely the blade, obtained by the traditional method and 2 is the second part of the part, namely the handle, obtained by additive manufacturing.

[0079] In one embodiment, Figure 2 represents a knife embodiment in which 1 is the blade obtained by the traditional method and 2 is the handle obtained by additive manufacturing. This figure also shows the joining surface between the blade and the handle, which is arranged in the stop 3.

[0080] In one embodiment, Figure 3 depicts a plurality of knife blades obtained by the traditional method, namely, stamping.

[0081] In one embodiment, Figure 4 depicts a knife embodiment in which the blade was produced by the traditional method and the handle by additive manufacturing.

[0082] In one embodiment, Figure 5 depicts three stops.

[0083] In one embodiment, Figure 6 represents the support 4 supporting the first part of the piece, the blades, for production of the second part of the cutlery piece, particularly the handles.

[0084] In one embodiment, Figure 7 represents the support 4 in which are inside the first parts 1 of the cutlery pieces, particularly the knife blades, and an upper top of said support 4, are the second parts 2 of the part, namely the cables, which are produced by additive manufacturing.

[0085] In one embodiment, Figure 8 represents the open support, with the knife blades arranged in the cavities, the stops and the cables extending from the stops visible.

[0086] In one embodiment, Figure 9 depicts cables with various geometries extending from the top of the support.

[0087] In one embodiment, Figures 6, 7, 8, 9, and 10 represent the support, JIG. This support comprises within it a plurality of cavities that have the inverse shape of said first part. The plurality of cavities receives a plurality of first parts, in this example blades, and is closed to produce the handle by additive manufacturing.

[0088] The term "comprises" or "comprising" when used in this document is intended to indicate the presence of the features, elements, integers, steps and components mentioned, but does not preclude the presence or addition of one or more other features, elements, integers, steps and components, or groups thereof.

[0089] The present invention is, of course, in no way restricted to the embodiments described in this document and a person with average knowledge of the area will be able to foresee many possibilities for modifying it and replacing technical characteristics with equivalent ones, depending on the requirements of each situation, as defined in the attached claims.

[0090] The following claims define additional embodiments of the present description.

Claims

CLAIMS 1. A method for obtaining a hybrid metal cutlery part by stamping and direct metal laser sintering additive manufacturing, wherein the cutlery part comprises a first part previously obtained by cutting and stamping and a second part obtained by additive manufacturing, wherein the first part is a shell, a blade, or teeth of the cutlery part, and wherein the second part is a handle of the cutlery part, said parts being joined at a joining surface, wherein said method comprises the following steps: providing a support for positioning the first part with the joining surface facing upwards towards the sintering laser; placing said first part on said support; depositing and sintering, by direct metal laser sintering, a metallic material in successive layers directly onto the joining surface of the first part to obtain said second part.

2. The method according to the preceding claim wherein the first part has a longitudinal axis and is arranged with the longitudinal axis in a vertical orientation.

3. A method according to any one of the preceding claims, wherein the first part comprises a stop on which said joining surface is arranged to receive the second part.

4. A method according to any one of the preceding claims wherein the support comprises a first plate and a second plate interlockable, wherein the support comprises at least one cavity formed between said plates and extending from a top of the support for receiving and supporting said first part.

5. Method according to any one of the preceding claims wherein the cavity is formed in one or both of said plates, in particular the support comprising couplers, from the English / asteners, more in particular bolts, from the English bolts, for joining said plates, preferably in which the cavity of the support is configured so that, when the first part is supported on said support, the stop protrudes from, or is flush with, a top surface of the support.

6. The method of any one of the preceding claims wherein the cavity has the inverse shape of said first part.

7. Method according to any one of the preceding claims, wherein the support comprises a plurality of cavities for receiving and supporting a plurality of first parts, in particular wherein the plurality of cavities are distributed equidistantly.

8. Method of obtaining a hybrid metal cutlery piece by stamping and direct metal laser sintering additive manufacturing, wherein the cutlery piece comprises a first part previously obtained by cutting and stamping and a second part obtained by additive manufacturing, wherein the first part is a shell, a blade, or teeth of the cutlery piece, and wherein the second part is a handle of the cutlery piece, said parts being joined at a joining surface, wherein said method comprises the following steps: depositing and sintering, by direct metal laser sintering, a metallic material in successive layers to obtain said second part; providing said first part; welding said parts together by said joining surface.

9. Method according to any one of the preceding claims comprising the additional step of removing excess material from said first part, in particular sanding and / or polishing the first part, and optionally comprising the previous step of removing a metal spike from said first part, wherein said metal spike is the result of stamping.

10. The method of any one of the preceding claims wherein the metallic material is steel.

11. The method of any one of the preceding claims wherein the laser is applied perpendicularly to said joining surface.

12. Method according to any one of the preceding claims, comprising a prior step of metal stamping of the first part.

13. The method of any one of the preceding claims wherein said joining surface is a planar surface or comprises a plurality of planar surfaces.

14. A metal piece of hybrid cutlery obtainable by the method according to any one of the preceding claims.

15. Hybrid metal cutlery piece, obtainable by stamping and direct metal laser sintering additive manufacturing process, in which the cutlery piece comprises: a first metal part previously obtained by cutting and stamping, and a second metal part obtained by additive manufacturing; in which the first part is a shell, a blade, or teeth of the cutlery piece; in which the second part is a handle of the cutlery piece; in which said parts are joined at respective joining surfaces; and in which the second part was obtained by depositing and sintering, by direct metal laser sintering, a metallic material in successive layers directly on the joining surface of the first part to obtain said second part.

16. A piece of cutlery according to any one of claims 14 and 15 wherein the piece is a fork, knife or spoon.

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