Additive Manufacturing Clamping for Precise Post-Processing
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Solution Overview
Problem
Additive manufacturing processes face challenges in post-processing, including accurate and fast clamping of parts with complex geometries, material wastage due to additional support elements, and loss of positioning information after separation from the build plate, leading to inefficiencies and increased rejection rates.
Innovation Solution
A method involving computer-aided design (CAD) data that integrates a first clamping element with parallel side surfaces and a center parallel vice jaw clamping system, where female and male clamping contours provide precise interaction and referencing, allowing for stable clamping and positioning of parts during post-processing without additional support elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If additional support elements (bolt elements) are manufactured along with the part to enable clamping, then the part can be clamped in standard clamping devices, but material is wasted due to the support elements not being part of the final part
Solution Approach 1:
The clamping element is segmented from the final part through a separable connection (screw connection, bayonet connection, or snap-fit connection). This allows the clamping element to be attached during additive manufacturing for easy clamping, then separated after post-processing to remove waste material. The segmentation enables the clamping function without permanently adding waste material to the final product.
Solution Approach 2:
The clamping element is preliminarily attached to the part during or after additive manufacturing but before post-processing. This preliminary attachment enables easy clamping and positioning during machining operations. After post-processing is complete, the clamping element is removed. The preliminary action provides the needed clamping capability temporarily without creating permanent waste.
2Productivity
If the part is separated from the build plate after additive manufacturing, then the part can be individually processed, but the positioning references are lost making accurate and fast clamping difficult
Solution Approach 1:
The positioning reference and clamping function are merged into a single integrated clamping element. The clamping element contains both the clamping interface (for mechanical attachment) and the positioning reference (geometric features for accurate positioning). This merging ensures that when the clamping element is attached to the part, it simultaneously provides both clamping and positioning reference functions, eliminating the loss of positioning information after separation from the build plate.
Solution Approach 2:
The clamping element acts as an intermediary between the part and the clamping device. It transfers the positioning reference from the original build plate context to the post-processing context. The clamping element's geometric features serve as the mediator that preserves positioning information through the separation and transfer process, enabling accurate positioning in the post-processing machine tool.
3Strength
If special fixtures are used to clamp complex geometry parts, then the parts can be stably clamped to withstand large forces, but additional costs are incurred
Solution Approach 1:
The clamping element is designed with universal functionality to work with standard clamping devices (three-jaw chucks, parallel-jaw chucks, or collet chucks). Instead of requiring special custom fixtures for each complex part geometry, the standardized clamping element can be attached to any part and then clamped using conventional clamping devices. This universality reduces device complexity and additional costs while maintaining stable clamping through proper force distribution.
4Ease of operation
If at least three additional support elements (bolt elements) are required for clamping, then the part can be clamped in three-jaw clamping systems, but more material is wasted
Solution Approach 1:
The clamping element is segmented from the final part through a separable connection, allowing it to be attached during additive manufacturing for easy clamping, then separated after post-processing to remove waste material. The segmentation enables the clamping function without permanently adding waste material to the final product.
Solution Approach 2:
The clamping element is designed with universal functionality to work with standard clamping devices (three-jaw chucks, parallel-jaw chucks, or collet chucks). Instead of requiring special custom fixtures for each complex part geometry, the standardized clamping element can be attached to any part and then clamped using conventional clamping devices. This universality reduces device complexity and additional costs while maintaining stable clamping through proper force distribution.
Data Source
Figure 1~3
Figure 4a~4b
Figure 5~7b
AI summary
The present invention is related to a method for manufacturing a part by additive manufacturing process comprising: a. providing CAD data defining the geometry of the part; b. providing CAD data defining the geometry of a first clamping element, wherein the geometry of the first clamping element is determined in consideration of the geometry of a second clamping element such that after the additive manufacturing process the first clamping element can be clamped into the second clamping element for holding the part in a desired position for post-processing; c. generating machining data based on the CAD data defining the geometry of the part and the CAD data defining the geometry of the first clamping element; d. forming the part and the first clamping element by additive manufacturing process based on the machining data. The first clamping element has at least two parallel side surfaces and the second clamping element has two vice jaws positioned in parallel to each other along the longitudinal direction of the second clamping element and in the clamped state, the two parallel side surfaces of the first clamping element are interacted with the vice jaws of the second clamping element, and wherein on at least one of the parallel side surfaces of the first clamping element a plurality of female clamping contours are provided for engaging with a plurality of male clamping contours provided on the vise jaw in the clamped state.