Metal AM Base Device Transfer for Precise CNC Separation
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Solution Overview
Problem
The existing methods for producing additive manufactured metal objects are time-consuming and labor-intensive due to the strong bond between the object and the base plate, requiring manual removal and difficulty in achieving accurate and repetitive machining operations.
Innovation Solution
A method involving building the object on a base device within a supporting means, allowing separation using a machining tool in a CNC machine, which also removes the built layer of metal, enabling direct transfer to CNC machining with precise mounting and repeated operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If manual removal of the built object from the base plate is used, then the strong bond between object and base plate is maintained, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
A first layer of metal is built on the base device before the actual object. This preliminary layer acts as a sacrificial element that is easily separable from the base plate, allowing the object to be removed without damaging the strong bond between the object and base plate. The first layer is subsequently removed from the base device, enabling reuse of the base plate.
2Strength
If manual removal of the built object from the base plate is used, then the strong bond between object and base plate is maintained, but manual work resources are required
Solution Approach 1:
A first layer of metal is built on the base device before the actual object. This preliminary layer acts as a sacrificial element that is easily separable from the base plate, allowing the object to be removed without damaging the strong bond between the object and base plate. The first layer is subsequently removed from the base device, enabling reuse of the base plate.
3Ease of manufacture
If the additive manufactured object is moved to CNC machine for machining, then subsequent operations can be performed, but mounting and adjustment becomes difficult and time-consuming
Solution Approach 1:
The base device is designed with features that enable direct connection to the CNC machine, merging the removal and mounting operations into a single integrated process. The base device can be directly mounted in the CNC machine spindle, eliminating the need for separate mounting and adjustment steps. This integration allows subsequent machining operations to be performed immediately after additive manufacturing.
4Ease of manufacture
If the additive manufactured object is moved to CNC machine for machining, then subsequent operations can be performed, but repetetiveness in dimensional tolerances becomes difficult to assure
Solution Approach 1:
The base device is designed with features that enable direct connection to the CNC machine, merging the removal and mounting operations into a single integrated process. The base device can be directly mounted in the CNC machine spindle, eliminating the need for separate mounting and adjustment steps. This integration allows subsequent machining operations to be performed immediately after additive manufacturing.
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
Facilitates efficient, low-labor handling and high accuracy in producing additive manufactured objects by simplifying the separation process and ensuring precise dimensional control during post-processing.
Implementation Method 1
In the laser powder-bed fusion method solid particles are applied in a thin layers and a three dimensional object is gradually formed layer-by-layer by fusing together particles with one or more laser beams
Implementation Method 2
Methods of producing an object by additive manufacturing include laser powder-bed fusion and powder-bed fusion by electron beam
Implementation Method 3
separating the built object from the base device by means of a machining tool in the CNC machine
Data Source
AI summary
The present invention relates to a method for producing an object of metal, wherein the object is built with an additive manufacturing process on at least one base device having a build surface at one end. The base device is part of a base device system, which includes the base device and a supporting means holding the base device in a fixed position during the additive manufacturing process. The method includes the steps of building the object on at least a part of the base device build surface with the additive manufacturing process, removing the base device from the supporting means, connecting the base device to a CNC machine provided with at least one machining tool, and separating the built object from the base device by means of a machining tool in the CNC machine.