Additive Workpiece Mounting Features for Precise Finish Machining
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Solution Overview
Problem
Rapid manufacturing techniques like selective laser sintering often require additional processing to achieve desired surface finishes and precision, as they struggle to accurately position and orient parts for subsequent machining operations, leading to inefficiencies and material wastage.
Innovation Solution
The method involves forming articles with kinematic mounting features during additive manufacturing, allowing them to be precisely positioned and oriented in machine tools for subsequent subtractive processes, such as machining, without the need for probing, thereby ensuring accurate processing and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rapid manufacturing techniques like selective laser sintering are used to manufacture articles, then manufacturing speed and ability to create complex geometries are improved, but positioning precision and orientation accuracy for subsequent machining operations deteriorate
Solution Approach 1:
The patent applies preliminary action by incorporating mounting features directly into the article during the additive manufacturing process itself. These features are pre-formed in the correct geometry and position, enabling precise positioning in subsequent machining operations without requiring time-consuming probing or measurement steps. This resolves the contradiction by preparing the positioning infrastructure in advance, maintaining high productivity while achieving the required precision.
Solution Approach 2:
The mounting features act as an intermediary element between the additively manufactured article and the machining fixture. These features provide a known reference geometry that mediates the positioning process, allowing the article to be accurately located and oriented on the machining device without direct measurement of the article's critical features. This intermediary approach maintains the productivity benefits of rapid manufacturing while achieving the precision needed for subsequent operations.
2Manufacturing precision
If traditional probing methods are used to position articles for machining after additive manufacturing, then positioning accuracy can be achieved, but processing time increases
Solution Approach 1:
The mounting features are created during the additive manufacturing process itself, performing the positioning preparation in advance. This eliminates the need for subsequent probing operations to determine article location and orientation, as the features provide known reference geometry from the outset. The preliminary creation of these features resolves the time-loss contradiction by preparing positioning infrastructure during the manufacturing process rather than adding separate positioning steps.
3Adaptability or versatility
If support structures are used during additive manufacturing to support overhanging features, then manufacturing of complex geometries is enabled, but surface quality and precision of features on supported surfaces deteriorate
Solution Approach 1:
The patent applies segmentation by separating the support structure from the final article geometry. The mounting features are designed to be formed on surfaces that were supported during additive manufacturing, and the support structures are subsequently removed. This segmentation allows the support structures to enable complex geometries during manufacturing while their removal restores the precision and surface quality of the previously supported features, resolving the contradiction between geometric versatility and surface precision.
4Manufacturing precision
If material is removed from surfaces with support structures to improve feature precision, then manufacturing precision is improved, but material wastage increases
Solution Approach 1:
The patent applies local quality by providing selective support structures only in regions where they are needed to enable complex geometries, rather than using extensive support throughout. The mounting features are strategically positioned on surfaces that require support during manufacturing but can be precisely finished afterward. This localized approach enables the necessary feature precision while minimizing the amount of material that would need to be removed, thus reducing material wastage while maintaining manufacturing precision.
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 enhances the precision and efficiency of machining operations by ensuring accurate positioning and orientation, reducing material wastage and processing time, and enabling the creation of complex geometries that would be difficult with traditional methods.
Implementation Method 1
Selective laser sintering is one such rapid manufacturing technique whereby products can be built up from powdered material, such as powdered metal, layer-by-layer. For example, a layer of powdered material can be applied to a bed of the laser sintering machine and a laser is then controlled so as to sinter or melt select parts of the powdered material
Data Source
AI summary
A method of manufacturing an article comprising: (a) performing an additive manufacturing process to firm an article in an initial state, the article comprising mounting features and being supported during the additive manufacturing process by support structures; and (b) performing a second manufacturing process to transform the article into a second state, which second manufacturing process is a subtractive process comprising: (i) mounting, via the mounting features formed during the additive manufacturing process, the article in a holding device of a machine for operating on the article, with the support structures or at least remnants thereof remaining on the article, and (ii) with the article so mounted in the holding device, processing at least one feature on a surface of the article on which the support structures were provided to remove material on the at least one feature provided by the support structures.