Automated Manufacturing of Additive Precursors with Reference Features
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Solution Overview
Problem
Subtractive manufacturing processes, such as rotary-tool milling, are labor-intensive and limited in geometry due to the need for manual loading and unloading of materials and restrictive geometries that can be economically manufactured.
Innovation Solution
A system and method for manufacturing a discrete object from an additively manufactured body of material, which includes a precursor to the discrete object and a reference feature, using an automated manufacturing device to generate a computer model incorporating the graphical representation of the precursor and reference feature, enabling precise location and processing within a subtractive manufacturing device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading and unloading of materials is used in subtractive manufacturing, then labor intensity increases, but manufacturing flexibility is maintained
Solution Approach 1:
The patent applies preliminary action by pre-manufacturing a body of material that includes both the precursor to the discrete object and reference features integrated into its structure. This preparatory step enables subsequent automated processing without manual intervention, as the reference features are already positioned to facilitate automatic loading and positioning in the subtractive manufacturing device.
Solution Approach 2:
The reference features on the body of material enable self-positioning and self-alignment during the manufacturing process. The automated manufacturing device can automatically locate and process the discrete object by recognizing these reference features, eliminating the need for manual loading and unloading operations while maintaining manufacturing flexibility.
2Adaptability or versatility
If traditional subtractive manufacturing is used, then geometric limitations exist, but manufacturing simplicity is maintained
Solution Approach 1:
The patent merges additive and subtractive manufacturing processes into a hybrid approach. The body of material is additively manufactured with complex geometries that would be difficult or impossible to create with traditional subtractive methods alone. Reference features are integrated into this additively manufactured body, enabling subsequent automated subtractive processing to achieve final precision while maintaining geometric versatility.
Solution Approach 2:
The additively manufactured body of material with integrated reference features serves as an intermediary between the design stage and final manufacturing. It combines the geometric freedom of additive manufacturing with the precision and automation benefits of subtractive manufacturing, allowing complex geometries to be realized without proportionally increasing process complexity.
3Loss of time
If automated manufacturing device with computer model is used, then setup time is reduced, but system complexity increases
Solution Approach 1:
The patent uses a computer model that digitally represents the body of material including the precursor to the discrete object and reference features. This digital copy guides the automated manufacturing device through the entire process, enabling automatic positioning and processing without manual setup. The reference features in the physical object correspond to features in the digital model, allowing automated recognition and processing.
Data Source
AI summary
A system for manufacturing a discrete object from an additively manufactured body of material including a precursor to a discrete object and at least a reference feature is disclosed. The system includes an automated manufacturing device, the automated manufacturing device including at least a controller configured to receive a graphical representation of precursor to a discrete object, receive a graphical representation of at least a reference feature on the precursor to the discrete object, and generate a computer model of the body of material, wherein the computer model of the body of material includes the graphical representation of the precursor to the discrete object and the graphical representation of the at least a reference feature.