CNC Machining Registration Fixture for Thermoplastic Parts
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Solution Overview
Problem
Current rapid prototyping techniques are expensive and do not accurately reflect the physical attributes of final parts, making them unsuitable for low-volume runs, while CNC machining with custom fixturing is time-consuming and costly for complex shapes, limiting its use in quick turn-around production.
Innovation Solution
A method and apparatus for total profile machining using a CNC machine, where a block of material is machined to define a side of the part and a registration/potting fixture is used to pack and solidify potting material, allowing for machining in multiple orientations without the need for custom fixturing, reducing waste and production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rapid prototyping techniques are used, then production speed is improved, but physical attributes and cost-effectiveness deteriorate
Solution Approach 1:
The patent combines additive manufacturing (rapid prototyping) and subtractive manufacturing (CNC machining) into a hybrid process. The additive process creates the basic part geometry quickly, then CNC machining refines critical surfaces to achieve precise physical attributes. This merging resolves the contradiction by obtaining both production speed and manufacturing precision.
Solution Approach 2:
The manufacturing process is segmented into distinct stages: additive manufacturing for bulk material deposition and CNC machining for precision surface finishing. Each process handles the portion of work it performs best at, allowing the system to achieve both speed and precision without compromise.
2Manufacturing precision
If CNC machining with custom fixturing is used, then manufacturing precision is improved, but production time and complexity increase
Solution Approach 1:
The patent uses disposable fixturing elements (such as sacrificial blocks or temporary clamps) instead of expensive, complex custom fixtures. These simple fixturing solutions are discarded after use, eliminating the time and cost of designing and fabricating permanent custom fixtures while still achieving the necessary dimensional accuracy during machining.
Solution Approach 2:
The patent employs universal fixturing systems that can accommodate multiple part geometries and orientations. Instead of designing unique fixtures for each part, a standardized fixture system with adjustable elements handles various machining operations, significantly reducing setup time and complexity while maintaining precision.
3Ease of manufacture
If custom fixturing is designed for complex shapes, then ease of manufacture is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex, expensive custom fixtures with simple, disposable fixturing elements. These temporary fixtures are easy to manufacture from standard materials and are discarded after a single use, eliminating the need for complex design and fabrication processes while providing adequate support for complex part geometries during machining.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables cost-effective, quick production of low-volume parts with accurate physical attributes by eliminating the need for custom fixturing and minimizing machining time, making it suitable for complex shapes and low-volume runs.
Implementation Method 1
The registration/potting fixture is used to pack and solidify potting material against the machined side of the part
Implementation Method 2
The registration/potting fixture may be cooled to accelerate solidification
Data Source
AI summary
A method and apparatus are provided for total profile machining of a part, such as from a block of thermoplastic polymer. A first side of the part is machined together with an encircling recess. A registration/potting fixture is placed into the encircling recess. The registration/potting fixture is used to evacuate air from the machined side of the part and to pressure pack degassed fluid potting compound against the machined side of the part. The registration/potting fixture is cooled such as with a coolant to solidify the potting material. Then the registration/potting fixture is used to fixture the block in a new orientation for CNC machining another side of the part. Upon removal of the potting material from the part, the total profile machined part is freed for shipment to the customer.