Cut-Layer Additive Parts With Tabs for Precise Segment Assembly
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Solution Overview
Problem
Traditional additive manufacturing techniques face challenges in producing large, complex parts like molds and tooling from non-porous materials like aluminum, due to high material removal times and difficulties in creating internal channels and accurately assembling cut layer parts, especially when using vacuum-generating machining apparatuses.
Innovation Solution
The method involves using cut layer additive manufacturing with tabs to hold parts in place during machining, forming puzzle joints, and labeling segments for accurate assembly, allowing for the production of parts from non-ferrous metals like aluminum without relying on vacuum hold-down forces and enabling precise internal channel creation.
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 from non-porous materials like aluminum, but significant time and material are required to remove excess material to achieve the desired shape
Solution Approach 1:
The patent divides the part into multiple thin layers or segments that can be manufactured separately and then assembled. This segmentation allows each layer to be processed independently, dramatically reducing the material removal time for large parts while maintaining geometric accuracy through precise layer-by-layer fabrication.
Solution Approach 2:
The patent transitions from traditional 3D subtractive manufacturing to a layered approach that effectively adds a dimensional aspect to the manufacturing process. By creating parts as stacked layers rather than removing material from a solid block, the method achieves complex geometries with significantly reduced machining time.
2Ease of manufacture
If traditional machining methods are used to create internal channels in solid blocks, then channels can be formed, but significant time and specialized equipment are required, and channels cannot be located in certain areas
Solution Approach 1:
By dividing the part into layers, internal channels can be created within individual layers or across multiple layers during the fabrication process itself, rather than requiring post-manufacturing machining. This eliminates the need for specialized drilling equipment and reduces build time significantly.
Solution Approach 2:
The patent performs preliminary actions by creating channels and features during the layer fabrication process itself, before final assembly. This preliminary formation of channels eliminates the need for subsequent machining operations and allows channels to be placed in locations that would be inaccessible to traditional machining tools.
3Productivity
If cut layer additive manufacturing is used to produce parts, then material removal time is reduced, but accurately assembling the cut layers and holding parts in place during machining presents challenges
Solution Approach 1:
The patent introduces tabs as intermediary features that facilitate the assembly of cut layers. These tabs act as mediators between layers, providing alignment features and connection points that simplify the assembly process. The tabs can be selectively removed after assembly, leaving clean joints between layers.
Solution Approach 2:
The patent replaces vacuum hold-down forces with a mechanical tab-based system for holding and assembling layers. This substitution eliminates the need for complex vacuum systems and provides a more reliable mechanical connection method that is better suited for metallic materials.
4Ease of operation
If vacuum-generating machining apparatuses are used for cut layer manufacturing, then parts can be held in place, but this method is not suitable for non-porous materials like aluminum
Solution Approach 1:
The patent replaces the vacuum-based holding system with a mechanical tab-based system that is compatible with non-porous materials like aluminum. The mechanical connection through tabs provides reliable part holding without requiring vacuum permeability, thereby expanding material compatibility.
Solution Approach 2:
Tabs serve as intermediaries between the machining apparatus and the workpiece, providing a mechanical connection method that works with any material regardless of porosity. This intermediary system eliminates the material compatibility limitations of vacuum-based systems.
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 and removing material during one or more first passes with the machining apparatus to form a plurality of segments in the sheet of material. The method also includes forming a tab by removing material during the one or more first passes with the machining apparatus for forming the segments, the tab connecting two segments within the sheet of material to each other and removing material with the machining apparatus to form joints on the segments.