Anchored Support Structures in Cut-Layer Parts for Internal Rigidity
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges in producing large, complex parts with internal structures like molds and tooling from non-porous materials such as metal, particularly aluminum, due to the difficulty in machining channels and incorporating internal support structures, which are time-consuming and costly.
Innovation Solution
A method and system for fabricating components using cut layer additive manufacturing that involves creating anchor points within layers to attach internal support structures, allowing for the integration of lighter, more rigid materials without the need for 3D printing, using a CNC router to form segments and joints, and incorporating support structures through anchor points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional subtractive manufacturing is used to produce large parts from solid blocks, then the parts can achieve desired geometry, but significant material is removed and production time increases
Solution Approach 1:
The patent divides the manufacturing process into discrete layers, where each layer is formed by cutting segments from sheets and assembling them. This segmentation allows material to be added only where needed rather than removing material from a solid block, significantly reducing material waste while maintaining geometric precision.
Solution Approach 2:
The patent transitions from three-dimensional subtractive machining to a layered assembly approach, where parts are constructed by stacking two-dimensional cut layers. This dimensional change enables net-shape or near-net-shape manufacturing, eliminating the need to remove large amounts of material while achieving complex geometries.
2Productivity
If aluminum molds are used for prototyping and short run production, then cost and production time are reduced, but they are not suitable for long-term production
Solution Approach 1:
The patent creates composite structures by assembling layered sheets with potentially different material properties. This allows the outer shell to be made from durable materials suitable for long-term production while maintaining the cost-effectiveness and production speed advantages of aluminum-like materials in specific layers or components.
Solution Approach 2:
Different regions of the manufactured part can use different materials optimized for their specific functions. Critical wear areas can use more durable materials while non-critical areas use lighter, cheaper materials, allowing the overall part to achieve both durability and cost-effectiveness.
3Adaptability or versatility
If internal channels are machined in solid blocks, then heating and cooling functionality is achieved, but significant time and specialized equipment are required
Solution Approach 1:
Instead of machining continuous channels through a solid block, the patent creates channels by forming them in individual layered sheets and assembling them. This segmentation allows channels to be created more efficiently in each layer without requiring complex multi-axis machining operations, significantly reducing production time while maintaining thermal control functionality.
Solution Approach 2:
The patent moves channel creation from three-dimensional machining to two-dimensional sheet fabrication followed by assembly. Channels are formed in flat sheets using simpler processes and then stacked to create the three-dimensional channel network, eliminating the need for specialized machining equipment and reducing time.
4Strength
If support structures are added to hollow parts in cut layer manufacturing, then structural integrity is improved, but the complexity of incorporating them increases
Solution Approach 1:
The patent combines the support structure fabrication with the main part fabrication by using the same cut-layer assembly process. Support structures are cut from sheets along with the main part components and assembled together in the same stacking process, eliminating the need for separate support structure manufacturing and reducing overall complexity.
Solution Approach 2:
The manufacturing process is designed to automatically accommodate support structures without requiring additional specialized steps. The same CNC cutting and assembly equipment used for the main part automatically creates and assembles support structures, allowing the system to serve multiple functions without increasing complexity.
Data Source
AI summary
A method of manufacturing a part includes removing material with a cutting machine to form a plurality of segments, at least two of the segments including an anchoring structure, connecting two or more segments to form a first layer, and connecting two or more additional segments to form a second layer. The method also includes connecting the first layer to the second layer and connecting a support structure directly to two of the anchoring structures.