Cut-Layer Part Anchoring for Internal Support Structures
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Solution Overview
Problem
Existing additive manufacturing techniques face challenges in efficiently producing large, complex parts with internal structures, such as molds and tooling, especially when using non-porous materials like aluminum, due to the need for significant material removal and the difficulty in incorporating internal support structures.
Innovation Solution
The method involves creating anchor points within the part's internal layers, allowing for the attachment of internal support structures. This is achieved by adding anchoring structures to selected layers, which protrude inwardly to facilitate the attachment of separate structural elements, enabling the use of lower-cost, more rigid, and lighter-weight materials.
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 be made with desirable materials like aluminum, but significant material removal time and cost are required
Solution Approach 1:
The part is divided into multiple thin layers that are manufactured separately and then stacked to form the complete part. This segmentation allows each layer to be processed independently and quickly, avoiding the need to machine away large volumes of material from a solid block while maintaining geometric accuracy through precise layer-by-layer construction.
2Temperature
If internal channels are added to molds for temperature control, then temperature regulation is improved, but machining these channels in solid blocks requires specialized equipment and significant time
Solution Approach 1:
The mold is constructed as a stack of thin layers, allowing cooling channels to be integrated directly into specific layers during the layer manufacturing process. This eliminates the need for complex post-processing machining of channels in solid blocks, as the channels are formed as part of the layered structure itself, reducing equipment requirements and manufacturing time.
Solution Approach 2:
Cooling channels are embedded within the layered structure of the mold, with channels nested inside specific layers rather than being machined into the exterior of a solid block. This nesting approach allows temperature control functionality to be integrated seamlessly into the mold structure without requiring specialized external equipment.
3Quantity of substance
If hollow structures are created in additive manufacturing, then material usage is reduced, but internal support structures are difficult to incorporate
Solution Approach 1:
The hollow structure is built as a stack of thin layers with internal support structures integrated into specific layers during the layer manufacturing process. This segmentation approach allows support structures to be easily incorporated into the hollow form without requiring complex post-assembly operations, as each layer can be independently configured with its own support elements.
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.