Cut-Part Layer Segmentation for Large Aluminum Additive Builds
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing additive manufacturing techniques for producing large parts, such as molds and tooling, face challenges including high costs and time-consuming programming processes, especially when dealing with non-porous materials like aluminum.
Innovation Solution
A software system and manufacturing method that automates the programming and production of layer segments for additive manufacturing, allowing for efficient production of parts from non-porous materials like aluminum by using CNC machining and CAD/CAM software, and incorporating features such as joint structures and dowel holes for accurate alignment and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional additive manufacturing techniques are used to produce large parts from non-porous materials like aluminum, then the parts can be manufactured with suitable material properties, but the programming process becomes time-consuming and costly
Solution Approach 1:
The patent divides the programming process into distinct modules: part geometry definition, automatic layer segmentation, joint structure generation, and nesting optimization. This modular approach reduces programming complexity and time by allowing each module to be independently configured and reused across different parts.
Solution Approach 2:
The system performs preliminary actions by automatically generating layer segments, joint structures, and nesting arrangements before manufacturing begins. The software pre-calculates optimal segment configurations and prepares all necessary programming elements in advance, eliminating time-consuming manual programming during production.
2Productivity
If layers are separated into multiple segments for additive manufacturing, then material nesting efficiency improves, but the complexity of programming and assembling segments increases
Solution Approach 1:
The patent implements universal joint structures that can be automatically generated and applied to any layer segment regardless of its specific geometry. These standardized joint designs work across different part types and sizes, reducing programming complexity while maintaining nesting efficiency.
Solution Approach 2:
The software system performs self-service by automatically generating segment configurations, joint structures, and nesting arrangements without requiring complex manual programming. The system autonomously optimizes segment layouts and generates assembly instructions, reducing the burden on operators while improving nesting efficiency.
3Manufacturing precision
If joint structures are added to layer segments for reconnection, then assembly accuracy improves, but the manufacturing complexity of each segment increases
Solution Approach 1:
The patent applies joint structures only at specific locations where segments need to be connected, rather than adding complexity throughout the entire segment. The joint structures are localized features with standardized geometries that provide precise alignment while minimizing impact on the overall manufacturing process.
Solution Approach 2:
The system optimizes joint structure parameters such as size, shape, and placement to balance alignment accuracy with manufacturing ease. By adjusting these parameters based on segment geometry and assembly requirements, the system achieves precise alignment without unnecessarily complicating the manufacturing process.
Data Source
AI summary
An additive manufacturing method includes receiving an electronic representation of a part with a control system, determining a plurality of layers for the electronic representation of the part, and separating one or more of the layers associated with the electronic representation of the part into a plurality of segments. The additive manufacturing method further includes adding a joint structure to two or more of the segments and generating instructions for controlling a machining apparatus based on the electronic representation of the part, the layers, the segments, and the joint structure.