Bonded Abrasive 3D Printing with Parallel Layer Processing
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Solution Overview
Problem
Conventional methods for producing bonded abrasive articles are time-consuming, limiting the range of potential products due to the time required for layer-by-layer construction, and existing continuous processes are constrained by factors such as powder flowability, drying time, and binder dispensing speed.
Innovation Solution
A modular additive manufacturing system that allows simultaneous execution of multiple steps in the 3D printing process, including depositing, leveling, compacting, and setting abrasive materials, using a continuous printer with a modular assembly line to increase throughput and control over rate-limiting steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional layer-by-layer construction methods are used to produce bonded abrasive articles, then manufacturing precision can be maintained, but production time increases significantly
Solution Approach 1:
The manufacturing process is segmented into multiple parallel workstations (depositing, leveling, compacting, setting) that operate simultaneously on different sections of the abrasive article, transforming the sequential layer-by-layer process into a parallel continuous production system
Solution Approach 2:
The process transitions from two-dimensional layer-by-layer construction to three-dimensional continuous production by adding the time dimension through simultaneous multi-step processing, allowing multiple operations to occur concurrently along the production line
2Productivity
If continuous manufacturing processes are used to reduce production time, then throughput increases, but the process becomes constrained by powder flowability, drying time, and binder dispensing speed
Solution Approach 1:
The system dynamically adjusts processing parameters at each workstation to optimize for continuous operation, with each station operating at its own optimal speed and the overall line speed being coordinated to balance throughput with material handling capabilities
Solution Approach 2:
Intermediate processing stations (leveling, compacting) are introduced between material deposition and final setting, acting as buffers that decouple the constraints of different process steps and allow each to operate independently at its optimal rate
3Loss of time
If modular additive manufacturing systems with simultaneous multi-step processing are implemented, then layer building time is reduced by more than half, but system complexity increases
Solution Approach 1:
The manufacturing system is divided into discrete modular workstations (depositing, leveling, compacting, setting) that can be independently designed, operated, and maintained, reducing the complexity burden on any single component while achieving overall process acceleration
Solution Approach 2:
Multiple previously sequential operations are merged into a single continuous pass through the manufacturing system, with all workstations processing the same article simultaneously, thereby reducing total cycle time despite increased system complexity
Data Source
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AI summary
A system for forming an abrasive article is presented. The system includes a workspace and an abrasive material dispenser that deposits a layer of abrasive material onto the workspace. The system also includes a leveler that levels a surface of abrasive material on the workspace. The system also includes a binder jet printer that dispenses a liquid binder onto the layer of abrasive material. The workspace is on a moving surface that moves the workspace between a dispensing position under the dispenser, a leveling position under the leveler, and a printing position, under the printer.