CNC Fixturing via Solidified Support Material
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Solution Overview
Problem
Current rapid prototyping techniques are expensive and inefficient for producing low-volume parts with complex geometries, and CNC machining is often hindered by the need for custom fixturing and lengthy tooling times, making it unsuitable for quick turn-around production of complex shapes, especially for low-volume runs.
Innovation Solution
A method and apparatus that allows customers to total profile machine their own parts by transmitting 3D CAD files to a computer processing location, generating CNC machining instructions for total profile machining, including features for fluid support material, enabling machining of a substantial majority of the part's surface area without custom fixturing, using a customer's own CNC mill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom fixturing is used for CNC machining of complex shapes, then manufacturing precision is improved, but device complexity and production time increase
Solution Approach 1:
The workpiece material block itself serves as the fixture through the embedded registration feature. The block's own geometry (with the registration feature that fits into the fixture recess) provides the positioning and support function, eliminating the need for separate custom fixturing devices. This self-service approach maintains manufacturing precision while dramatically reducing device complexity.
Solution Approach 2:
The registration feature embedded in the workpiece block serves multiple functions: it provides positioning, support during machining, and orientation reference. This multi-functional element eliminates the need for separate fixture components, reducing overall device complexity while maintaining the precision required for complex shape machining.
2Manufacturing precision
If custom fixturing is designed and fabricated, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The registration feature is pre-formed as an integral part of the workpiece block during the block fabrication process, before machining begins. This preliminary action eliminates the need for subsequent fixture design and fabrication time, as the positioning feature is already in place when machining starts.
Solution Approach 2:
The workpiece block provides its own positioning and support functions through the embedded registration feature, eliminating the time-consuming process of designing and fabricating separate custom fixtures. The block itself serves the fixture function that would otherwise require external components.
3Productivity
If CNC machining is used for low-volume parts, then productivity is improved, but device complexity increases due to custom fixturing requirements
Solution Approach 1:
The workpiece block serves as its own fixture through the embedded registration feature, enabling CNC machining of complex shapes without requiring custom fixturing. This self-service approach maintains high productivity for low-volume production while eliminating the device complexity associated with custom fixture design and fabrication.
Solution Approach 2:
The registration feature is segmented into distinct functional elements (fixture recess, protruding feature) that can be independently designed and manufactured. This segmentation allows the positioning function to be integrated into the block without requiring complex overall fixture designs, simplifying the system while maintaining productivity.
4Productivity
If total profile machining is performed, then productivity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The workpiece block provides self-positioning and self-support through the embedded registration feature, enabling stable total profile machining. This self-service fixture system maintains manufacturing precision during high-speed material removal by ensuring consistent workpiece positioning and support throughout the machining process.
Solution Approach 2:
The registration feature is pre-formed in the workpiece block before machining begins, establishing precise positioning and support conditions in advance. This preliminary action ensures that high-precision surfaces can be machined at high speeds, as the positioning reference is already in place to guide the machining process.
Data Source
AI summary
A customer transmits their 3D CAD file for a part to be total profile machined. Computer analysis of the transmitted CAD file produces CNC machining instructions, which are transmitted back to an address defined by the customer. The customer can then use the transmitted CNC machining instructions to total profile machine their own part using their own CNC mill at the location where the part is likely needed. The transmitted instructions include not only the tool paths for CNC machining of the total profile of the part, but also for additional features formed into the encircling portion of a material block from which the part is to be total profile machined. For instance, the CNC machining instructions transmitted back to the customer can define a registration recess and/or channels or undercuts for fluid support material on an A-side of a material block. After the A-side of the block is machined, the customer adds and solidifies fluid support material into the machined recess. The CNC mill is then used to machine a support surface into a portion of the solidified support material surface. A registration fixture is applied into contact with the support surface CNC machining on the B-side of the material block is then performed while the part is supported by the solidified support material, substantially separating the part from the encircling block of material. The support material is then removed, such as by dissolving, freeing the part from the encircling block of material.