Cut-Layer Mold Assembly With Internal Cooling Channels
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Solution Overview
Problem
The existing methods for producing metal molds, such as aluminum molds, are inefficient due to the need for significant material removal and machining time, especially for large or complex designs, which increases costs and limits the ability to incorporate internal channels for temperature control.
Innovation Solution
A method using cut layer additive manufacturing with a CNC router to create molds from sheet materials, allowing for nested sections that are machined to fit together with alignment holes and channels for coolant, air, or adhesive, reducing the need for extensive machining and enabling easier integration of internal channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional subtractive manufacturing is used to produce aluminum molds from solid blocks, then the molds can be produced with suitable cost for prototyping, but significant material removal time is required which increases production time
Solution Approach 1:
The mold is divided into multiple layers that are manufactured separately and then stacked together. Each layer is cut from sheet material and contains features such as alignment holes, coolant channels, and registration marks. This segmentation allows parallel manufacturing of multiple layers simultaneously, dramatically reducing production time while maintaining cost-effectiveness for prototyping applications.
Solution Approach 2:
The invention transitions from three-dimensional subtractive machining of solid blocks to a layered approach where molds are constructed by stacking two-dimensional sheets. This dimensional change enables faster manufacturing since sheets can be cut and prepared more quickly than blocking, and layers can be manufactured in parallel rather than sequentially removing material from a solid form.
2Ease of manufacture
If traditional subtractive manufacturing is used to machine internal coolant channels in solid blocks, then the channels can be created, but the process requires specialized equipment and significant machining time
Solution Approach 1:
Coolant channels are integrated into individual layers during the cutting process rather than being machined through solid blocks. Each layer can contain pre-formed channels, and when layers are stacked, continuous coolant pathways are created through the entire mold structure. This eliminates the need for complex multi-axis machining operations and specialized equipment.
Solution Approach 2:
Coolant channels and other internal features are incorporated into the layer design before manufacturing. The CNC router or cutting machine creates channels, alignment holes, and other features directly in the sheet material during the cutting process, rather than requiring subsequent machining operations after the mold is assembled from solid blocks.
3Ease of manufacture
If large blocks of material are used to create large molds, then the molds can be produced, but more than half the initial material may need to be removed which increases waste and cost
Solution Approach 1:
The mold design is segmented into multiple layers that are cut from sheet material. This allows the mold to be constructed with minimal material waste since sheets can be nested and cut to optimize material usage. The layered structure only includes the material needed for the mold cavity and necessary support, eliminating the waste associated with removing excess material from large solid blocks.
Solution Approach 2:
The invention changes the fundamental parameter of material form from solid blocks to sheet material. This parameter change enables more efficient material utilization through nesting and optimized cutting patterns, reducing material waste while still allowing the production of large mold structures.
4Manufacturing precision
If solid blocks are machined to create complex mold geometries, then the final shape can be achieved, but the process is time-consuming and limits design flexibility for certain channel locations
Solution Approach 1:
Complex mold geometries are achieved by stacking multiple layers, each containing specific features. This segmentation allows different regions of the mold to be optimized independently, with each layer designed and manufactured separately. The final assembled mold achieves the desired complex geometry while significantly reducing build time compared to machining solid blocks.
Solution Approach 2:
The transition to layered construction enables design flexibility that is not achievable with solid block machining. Channels, cooling paths, and other features can be positioned in locations that would be difficult or impossible to machine from solid material, while maintaining manufacturing precision through precise layer stacking and alignment mechanisms.
Data Source
AI summary
A method of manufacturing a part using a cutting machine includes placing a non-porous sheet on a surface of a material cutting machine, removing material from the non-porous sheet to form a plurality of sections of the part, and while the non-porous sheet is present on the material cutting machine, forming fastening holes within the sections. The method further includes removing the sections from a remainder of the sheet, placing the sections together such that each section of the part abuts another section, and inserting fasteners through the fastening holes of the sections.