Cut-Layer Segment Joints for Internal Channels and Surface Finish
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Solution Overview
Problem
Traditional additive manufacturing techniques for producing large, complex parts like molds and tooling from nonporous materials like aluminum are inefficient due to the need for significant material removal and specialized equipment, especially for creating internal channels and achieving a solid surface finish.
Innovation Solution
A method involving cutting and machining of sheet materials to form layer segments with complementary shapes and slots, using a connecting device to secure these segments tightly together, allowing for efficient assembly and machining of parts without the need for extensive material removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional additive manufacturing uses large blocks of nonporous material like aluminum, then the part can achieve desired strength and surface finish, but significant material removal time and specialized equipment are required
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 machined with complementary shapes at the interfaces. This segmentation allows each layer to be processed independently with minimal material removal, while the stacked assembly achieves the desired complex geometry and surface finish without requiring extensive machining of a solid block.
Solution Approach 2:
The invention transitions from traditional three-dimensional solid block machining to a layered two-dimensional sheet stacking approach. By cutting layers from sheets and stacking them with complementary interface shapes, the method achieves complex 3D geometries with minimal material removal, eliminating the need to machine away half or more of a solid block as required by conventional methods.
2Ease of manufacture
If traditional methods machine internal channels in solid blocks, then channels can be created, but significant time and specialized equipment are required
Solution Approach 1:
Internal channels are created by forming complementary shapes and slots at the interfaces between stacked layers. This allows channels to be constructed from the outside in, layer by layer, rather than requiring complex internal machining of a solid block. The channels are formed by the arrangement and connection of layered segments, eliminating the need for specialized equipment and significantly reducing build time.
3Loss of time
If cut layer additive manufacturing is used, then material removal time is reduced, but achieving tight connections between layers is challenging
Solution Approach 1:
Complementary asymmetric shapes are formed at the interfaces between adjacent layers. These asymmetric mating surfaces fit together like puzzle pieces, creating tight mechanical connections between layers. The asymmetric geometry prevents misalignment and ensures proper positioning, while the interlocking shapes provide mechanical strength to the joints without requiring extensive material removal or specialized joining equipment.
4Duration of action of stationary object
If aluminum molds are produced for long-term production, then durability is improved, but the cost and production time increase significantly
Solution Approach 1:
The mold is manufactured as stacked layers that can be produced quickly using cut layer additive manufacturing techniques. This layered approach dramatically reduces production time compared to traditional solid block machining or long-term 3D printing processes. The segmented structure maintains sufficient strength and durability for the intended application lifecycle while enabling rapid fabrication at lower cost.
Data Source
AI summary
A method of manufacturing a part with a plurality of cut segments includes receiving a sheet of material with a machining apparatus, removing material with the machining apparatus to form a plurality of segments in the sheet of material, and forming complementary shapes in ends of two or more segments of the plurality of segments. The method further includes forming slots in the two or more segments, aligning the slots in the two or more segments to form a cavity, and inserting a connecting device to fill the cavity.