Continuous Abrasive Wheel 3D Printing via Binder Jetting
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Solution Overview
Problem
The time-consuming process of building each layer in conventional additive manufacturing methods for bonded abrasive articles limits the range of cost-effective products that can be produced, as it reduces the throughput and increases production costs.
Innovation Solution
Implementing a continuous 3D-printing process where all steps are performed simultaneously, such as powder bed binder jetting, to reduce layer building time by more than half and increase throughput, allowing for the simultaneous manufacture of multiple parts and varying abrasive article properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing methods are used to build each layer sequentially, then manufacturing precision can be maintained, but productivity is reduced and production time increases
Solution Approach 1:
The patent combines multiple layer building operations into a single simultaneous process. Multiple abrasive articles are manufactured in parallel within the same build chamber, with multiple nozzles depositing binder material simultaneously at different locations. This merging of sequential operations into parallel simultaneous operations maintains precision while dramatically improving productivity and reducing production time.
Solution Approach 2:
The patent implements continuous manufacturing by eliminating idle time between layer building operations. The build platform continuously rotates while multiple nozzles simultaneously deposit binder material for multiple articles. The process maintains continuous useful action by ensuring that while one article is being built, other articles are simultaneously being built, maximizing the utilization of the manufacturing system throughout the entire process.
2Device complexity
If conventional additive manufacturing methods are used with sequential layer building, then device complexity can be kept moderate, but loss of time increases significantly
Solution Approach 1:
The patent segments the manufacturing process by dividing the build chamber into multiple independent working zones, each with its own nozzle system. This segmentation allows simultaneous operation of multiple deposition systems without requiring complex interconnections. The build platform is segmented into multiple radial zones that can be independently addressed, reducing overall system complexity while enabling parallel manufacturing and significantly reducing total build time.
3Ease of manufacture
If conventional additive manufacturing methods are used, then manufacturing cost can be controlled, but productivity reduction leads to increased production costs
Solution Approach 1:
The patent implements multi-functionality by designing a single build chamber and control system that can simultaneously manufacture multiple different abrasive articles with varying properties. The system can produce articles with different abrasive materials, bond types, and geometric configurations in parallel using the same fundamental manufacturing process. This universality increases productivity and throughput while maintaining cost control by avoiding the need for separate dedicated manufacturing lines for each article type.
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 significantly reduces the time required for each layer, increases the printer's throughput, and enables the production of a wider range of abrasive articles with varying properties, enhancing efficiency and cost-effectiveness.
Implementation Method 1
a binder material is jetted onto the abrasive particles to adhere them together
Implementation Method 2
a binder material is jetted onto the abrasive particles
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3~4A
AI summary
The present disclosure provides systems and methods for making bonded abrasive articles. The bonded abrasive wheel may be formed using a continuous layer approach, such as a spiral building of abrasive articles. The spiraling building of abrasive articles may be used to form cylindrical bodies that includes a continuous spiral-shaped abrasive layer. The continuous spiral-shaped abrasive layer may be used to form bonded abrasive wheels, such as may be used in face-grinding, edge-grinding, cutting, drilling, or other abrasive articles.