Additive Part Mounting Features for Precise Finish Machining
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Solution Overview
Problem
Rapid manufacturing techniques like selective laser sintering struggle to achieve precise surface finishes and feature precision in complex parts, such as dental restorations, due to limitations in positioning accuracy and orientation during subsequent machining processes.
Innovation Solution
Incorporating kinematic mounting features in the additive manufacturing process to securely position and orient articles within machine tools, allowing for precise machining and processing without the need for probing, by engaging with corresponding features on the machine's holding device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing is used to form complex parts rapidly, then manufacturing speed and complexity capability are improved, but positioning accuracy and surface finish precision deteriorate
Solution Approach 1:
The patent incorporates mounting features directly into the article during the additive manufacturing process, before the article is removed from the build plate. This preliminary action establishes precise positioning capabilities in advance, eliminating the need for post-manufacturing positioning operations and enabling accurate subsequent machining while maintaining rapid manufacturing benefits
Solution Approach 2:
The mounting features act as an intermediary element between the article and the machine tool holding device. These features provide a precise interface that transfers and maintains accurate positioning information through the manufacturing process, enabling the article to be accurately positioned in subsequent machining operations despite the imprecise nature of additive manufacturing
2Adaptability or versatility
If additive manufacturing is used to create complex geometries, then design flexibility is improved, but surface finish quality deteriorates
Solution Approach 1:
Mounting features are integrated into the article during additive manufacturing, establishing a stable reference framework before surface finishing operations. This allows subsequent machining to achieve high surface finish quality on specific features while maintaining the overall complex geometry created by additive manufacturing
3Manufacturing precision
If mounting features are added to articles for subsequent machining, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The mounting features are merged with the article's support structures or built-in geometric elements during additive manufacturing. This integration combines the positioning function with existing article features, avoiding the need for separate mounting components and minimizing the increase in overall device complexity
Solution Approach 2:
The mounting features are designed to serve multiple functions: they provide positioning accuracy for subsequent machining, maintain orientation during handling, and can serve as attachment points for support structures. This multi-functionality reduces the need for additional specialized features, keeping the overall structure relatively simple
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 ensures accurate positioning and orientation of parts, reducing errors and processing time, and enabling efficient machining of complex geometries with improved surface finishes and fit, particularly in dental restorations, by using kinematic mounting features to constrain the article's position and orientation within the machine's operating volume.
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
Implementation Method 2
a laser is then controlled so as to sinter or melt select parts of the powdered material
Data Source
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Figure 3a~3b
Figure 4a~4b
AI summary
A method of manufacturing an article comprising: (a) performing an additive manufacturing process (110) to form an article (20) in an initial state, the article (20) comprising mounting features (18) and being supported during the additive manufacturing process (110) by support structures (23); and (b) performing a second manufacturing process to transform the article (20) into a second state, which second manufacturing process is a subtractive process comprising: (i) mounting (130), via the mounting features (18) formed during the additive manufacturing process (110), the article (20) in a holding device (25) of a machine for operating on the article (20), with the support structures (23) or at least remnants thereof remaining on the article (20), and (ii) with the article (20) so mounted in the holding device (25), processing (140) at least one feature (6, 14) on a surface of the article (20) on which the support structures (23) were provided to remove material on the at least one feature (6, 14) provided by the support structures (23).