Additively Deposited Cutting Edge for Lower-Waste Tool Manufacturing

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Solution Overview

Problem

Existing methods for manufacturing cutting tools with hard cutting edges are costly and time-consuming due to the need for manual brazing of hard materials onto a cylindrical blank, and there is a desire for an automated process that reduces material waste and production time.

Innovation Solution

A two-step process combining additive deposition of hard materials like tungsten carbide onto a base substrate, followed by subtractive machining to form the cutting edge configuration, utilizing directed energy deposition (DED) and subtractive manufacturing techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If manual brazing is used to form cutting edges on a cylindrical blank, then the cutting tool achieves high hardness and wear resistance, but the production process becomes costly and time-consuming

Engineering Contradiction:

Improvehardness and wear resistance of cutting edgeVSAvoidproduction cost and time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent replaces the manual brazing process with an automated additive manufacturing process. A robotic arm equipped with a wire arc additive manufacturing (WAAM) system automatically deposits hardfacing material (such as tungsten carbide-containing alloys) onto the cylindrical blank to form the cutting head, eliminating manual labor and significantly reducing production time and cost while maintaining the hardness and wear resistance of the cutting edge

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the manufacturing approach from subtractive (brazing and grinding) to additive manufacturing. By using wire arc additive manufacturing with controlled deposition parameters, the process achieves automated formation of cutting edges with desired hardness properties, reducing both production time and cost while maintaining material performance

Inventive Principle:

Principle #35Parameter changes

2Strength

If the entire cutting tool is formed from high hardness material, then the cutting edge performance is improved, but the material cost increases significantly

Engineering Contradiction:

Improvehardness of cutting edgeVSAvoidamount of expensive hard material used

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

The patent applies local quality by forming only the cutting head and cutting edges from hard high-speed steel or tungsten carbide-containing material using additive manufacturing, while the body of the cutting tool can be formed from less expensive material. This localized application of hard material reduces the quantity of expensive material required while maintaining cutting edge performance

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent segments the cutting tool into distinct functional zones: the cutting head formed by additive manufacturing with hard material, and the body that may use different material properties. This segmentation allows optimized material usage where high hardness is only required at the cutting edge, reducing overall material cost

Inventive Principle:

Principle #1Segmentation

3Productivity

If automated additive deposition is used instead of manual brazing, then production time and cost are reduced, but the process complexity increases

Engineering Contradiction:

Improveproduction time and automation levelVSAvoidcomplexity of manufacturing process

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces complex manual brazing operations with automated wire arc additive manufacturing controlled by robotic systems and computer programming. While the equipment is more complex, the process eliminates manual skill requirements, reduces production time, and enables consistent quality through automated control, representing a trade-off that favors productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method enables the production of cutting tools with high hardness and toughness, reducing production costs and time, minimizing defects, and allowing for customizable and complex edge profiles, while conserving critical materials.

Implementation Method 1

additive deposition of a tool material comprising tungsten carbide, TaNbC, a tungsten carbide containing alloy or composite, or a TaNbC containing alloy or composite onto a base substrate

Methodology Applied

Scientific EffectDirected energy deposition: Laser Beam Welding

Implementation Method 2

additive deposition...utilizing directed energy deposition (DED)

Methodology Applied

Scientific EffectThermal melting: Melting

Data Source

PatentUS20250339900A1Process of forming a cutting tool with additively deposited cutting edge

Publication Date: 2025.11.06 COMMONWEALTH SCI & IND RES ORG

AI summary

The present invention provides a process of forming a cutting tool comprising the steps of: additive deposition of a tool material comprising at least one of: tungsten carbide, TaNbC, a tungsten carbide containing alloy or composite, or a TaNbC containing alloy or composite onto a base substrate having a longitudinal axis, said tool material being deposited onto the base substrate to form a deposit body configured to form at least one cutting formation therein; and subsequently subtracting selected portions of the deposit body to produce at least one cutting formation having a selected cutting edge configuration, thereby forming the cutting tool.