Cut-Layer Support Structures Using Anchoring Points
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing techniques face challenges in producing large, complex parts, especially those requiring internal support structures, due to the difficulty in incorporating channels and support structures within layers, particularly in cut layer processes, which are time-consuming and costly when using solid blocks of material.
Innovation Solution
The method involves creating anchor points within layers to facilitate the attachment of internal support structures, allowing for the use of lighter, more rigid materials, and enabling the assembly of parts without the need for 3D printing, by using a machining apparatus to form segments and connect them with anchor points and support structures.
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 is excessive
Solution Approach 1:
The patent divides the manufacturing process into discrete layers that are cut from material and stacked sequentially. Each layer is an independent segment that can be prepared separately, allowing parallel processing and eliminating the need to machine entire large parts from solid blocks, thus dramatically reducing production time while maintaining geometric accuracy.
Solution Approach 2:
The patent transitions from traditional 3D subtractive manufacturing to a layered 2D-cut-and-stack approach. By cutting layers in 2D from flat material and stacking them to build 3D geometry, the process avoids the time-consuming removal of material from solid blocks while achieving complex three-dimensional shapes.
2Adaptability or versatility
If channels are machined into solid blocks for internal circulation, then internal channels can be created, but significant time and specialized equipment are required
Solution Approach 1:
The patent incorporates channels by cutting them into individual layer segments before stacking. This allows channels to be created as integral features of each layer rather than requiring complex multi-axis machining of solid blocks, significantly reducing machining time and equipment requirements while maintaining channel complexity and adaptability.
3Strength
If support structures are added to additive manufactured parts, then structural integrity is improved, but the part becomes heavier
Solution Approach 1:
The patent integrates support structures as integral features within specific layers where needed for structural integrity, rather than adding uniform support throughout the entire part. This localized approach provides necessary strength while minimizing additional weight, as supports are only placed where structurally required.
4Productivity
If cut layer additive manufacturing is used instead of 3D printing, then material costs are reduced and production time is decreased, but incorporating internal support structures becomes more difficult
Solution Approach 1:
The patent resolves the complexity of incorporating support structures in cut layer manufacturing by integrating them as integral features of the layer segments themselves. Rather than attempting to add supports after assembly, the support structures are cut into the layers during the layer preparation stage, simplifying the overall process while maintaining the productivity and cost advantages of cut layer manufacturing.
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.