Hybrid Manufacturing Build Orientation for Accessible Support Removal

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Solution Overview

Problem

Current manufacturing processes lack a systematic approach to optimize build orientation in additive manufacturing based on support structure accessibility, particularly for hybrid systems combining additive and subtractive processes, which complicates the removal of sacrificial supports using subtractive tools.

Innovation Solution

An automated optimization method and system that determines the optimal build orientation by analyzing the inaccessibility measure field for a set of tool assemblies and fixtures, ensuring the near-net shape can be efficiently fabricated using additive manufacturing and post-processed with subtractive machines, minimizing the cost of inaccessible support structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If additive manufacturing is used to fabricate complex parts, then manufacturing flexibility and geometric complexity are improved, but support structures become inaccessible and difficult to remove using subtractive tools

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidsupport structure accessibility

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The system performs preliminary analysis of support structure accessibility before the additive manufacturing process by defining multiple potential build orientations and evaluating their inaccessibility measures. This allows the optimal build orientation to be selected in advance, ensuring that support structures will be accessible for subsequent subtractive removal, thus resolving the accessibility issue before manufacturing begins.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically evaluates multiple build orientations and selects the optimal one based on accessibility criteria. By making the build orientation variable and selectable rather than fixed, the system adapts to the specific geometry of the part and tool assembly characteristics to maximize support structure accessibility while maintaining manufacturing flexibility.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If multiple build orientations are evaluated to optimize support accessibility, then support structure accessibility is improved, but computational complexity and process planning time increase

Engineering Contradiction:

Improvesupport structure accessibilityVSAvoidprocess planning complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The system replaces manual process planning with an automated computational method that defines multiple build orientations, calculates inaccessibility measures, and selects the optimal orientation automatically. This substitution of manual mechanical process planning with automated computational analysis reduces the complexity burden on operators while improving support accessibility evaluation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates virtual models and simulations of multiple build orientations and their corresponding support structures before actual manufacturing. By working with digital copies and inaccessibility measure fields rather than physical prototypes, the system can evaluate multiple scenarios efficiently without increasing physical complexity.

Inventive Principle:

Principle #26Copying

3Ease of operation

If build orientation is optimized for support accessibility, then subtractive tool accessibility is improved, but the number of constraints and evaluation criteria increase

Engineering Contradiction:

Improvesubtractive tool accessibilityVSAvoidevaluation criteria complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The system changes the evaluation from qualitative assessments to quantitative parameter-based evaluation by defining inaccessibility measure fields and calculating numerical values for each build orientation. This parameterization of accessibility criteria allows systematic comparison and automated selection of optimal orientations while making the evaluation process more manageable despite increased complexity.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11577321B2Hybrid manufacturing system and method that reduces inaccessible support structures

Publication Date: 2023.02.14 XEROX CORP

AI summary

A geometry model is defined of a part targeted for a manufacturing operation that includes an additive process followed by a subtractive process. Potential build orientations of the geometry model used in the additive processes are defined, as are one or more removal tools of the subtractive process. For each of the potential build orientations, supports that are used by the additive process at the orientation are determined. One of the build orientations is selected that minimizes portions of one of the supports that are inaccessible via at least one of the removal tools.