3D-Printed Vacuum Locking Jig for Faster Workpiece Holding
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Solution Overview
Problem
Existing methods for creating locking jigs to hold workpieces during machining are cumbersome, material-intensive, time-consuming, and result in significant waste, with manual processes leading to inefficiencies and variable air pressure due to rough surfaces.
Innovation Solution
The method involves manufacturing a locking jig using additive production techniques, such as 3D printing, to create a lattice structure with internally hollow annular bodies, allowing for efficient design-to-production transition, reduced material usage, and improved vacuum transmission with minimized load losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods of making locking jigs by superimposing and gluing multiple boards are used, then the locking jig can be made with available materials, but the process is complicated, time-consuming (3-4 weeks), and generates considerable waste material
Solution Approach 1:
The patent replaces the traditional mechanical system of superimposing, gluing, and milling multiple wooden boards with an additive manufacturing system (3D printer) that deposits material layer by layer to directly form the locking jig and its internal vacuum channels, eliminating the need for manual assembly and extensive machining operations
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from subtractive (milling away large blocks of wood) and assembly-based (gluing multiple boards) to additive (depositing material layer by layer), which fundamentally transforms the production process into a single-step formation that requires no assembly or waste-generating removal operations
2Manufacturing precision
If traditional milling methods are used to create the locking jig shape and vacuum channels, then the desired shape can be achieved, but considerable volume of waste material is generated and the process is time-consuming
Solution Approach 1:
The patent replaces the subtractive mechanical milling system with an additive deposition system that builds the locking jig and its internal vacuum transmission channels directly in the desired shape, eliminating the need to remove large volumes of material and thereby preventing waste generation
Solution Approach 2:
The patent performs preliminary digital modeling and path planning of the entire locking jig structure including internal vacuum channels before manufacturing, allowing the additive system to directly deposit material in the final desired configuration without requiring subsequent machining or shaping operations that would generate waste
3Ease of manufacture
If manual milling is used to create vacuum transmission channels, then the channels can be formed, but the surfaces have excessively great roughness causing unacceptable load losses in air pressure
Solution Approach 1:
The patent replaces manual milling operations with an additive manufacturing system that deposits material in a controlled layer-by-layer manner, inherently creating smoother internal surfaces for vacuum transmission channels that reduce air friction and prevent unacceptable load losses in air pressure
Solution Approach 2:
The patent changes the surface finish parameter by using additive manufacturing's inherent layer deposition process, which creates uniformly smooth internal surfaces compared to manual milling, thereby improving vacuum transmission efficiency and maintaining consistent air pressure throughout the system
4Quantity of substance
If wooden boards are used to make the locking jig, then the material is readily available, but wood is hygroscopic and requires temperature control and prolonged pressure application during gluing
Solution Approach 1:
The patent changes the material parameter from hygroscopic wood to materials suitable for additive manufacturing (such as plastics or resins) that do not absorb humidity and swell, thereby eliminating the need for temperature control and prolonged pressure application during the manufacturing process
Solution Approach 2:
The patent replaces the complex assembly process involving gluing multiple wooden boards with temperature and pressure control with a single-step additive manufacturing process that deposits material directly into the final shape, eliminating the need for assembly operations and associated complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables rapid production of customized locking jigs with reduced material waste and weight, improved air pressure consistency, and significantly shorter production times, addressing the inefficiencies of traditional methods.
Implementation Method 1
applying a vacuum that, through the holes 109 and the further holes, enables the resting workpiece P to adhere and remain stationary with respect to the support surface 111 of the locking jig 101
Data Source
AI summary
A method for holding a workpiece to be machined including the steps of: includes manufacturing a locking jig for locking the workpiece on a support base by additive production techniques wherein the locking jig includes a wall defining a loop. Irregularities present on at least one end of the wall arrangement are eliminated to define a support surface for the workpiece to be machined. A seat is formed in at least one end of the wall for housing a seal. At least one opening is formed on the support base and connected to at least one inner space of the loop on one side and with a suction device on the other side. A vacuum is supplied through the opening and the inner space which enables the workpiece to stick to and remain stationary with respect to the support surface during machining of the workpiece.