3D Printed Diamond-Polymer Sharpening Tool

The patent replaces traditional mechanical shaping and polishing processes with a 3D printing technology that directly creates the abrasive tool with its final functional geometry. The additive manufacturing process eliminates the need for labor-intensive cutting, shaping, and polishing operations while producing consistent results without requiring expensive diamond and metal composite materials.

The invention changes the manufacturing parameters from traditional subtractive methods (cutting, shaping, polishing) to additive manufacturing parameters (layer deposition, infill patterns, material extrusion). This parameter transformation enables direct production of complex abrasive tool geometries that would be impossible or excessively costly to create using conventional methods.

The patent replaces high temperature firing and manual polishing procedures with a controlled 3D printing process that incorporates abrasives during layer deposition. The additive manufacturing technique allows for precise placement of abrasive particles within the ceramic matrix without requiring post-manufacturing polishing or high temperature treatment.

The invention performs the abrasive particle embedding action during the 3D printing process itself, rather than requiring separate polishing operations after manufacturing. The abrasive particles are incorporated into the ceramic layers as they are being deposited, so the tool is pre-prepared with its final abrasive surface without needing subsequent labor-intensive polishing.

The patent creates a composite material system combining polymeric binder with embedded abrasive particles (such as diamond, cubic boron nitride, or ceramic abrasives) within the 3D printed structure. This composite approach provides the manufacturing advantages of polymeric materials while the embedded abrasives deliver reliable metal honing performance and the rigid 3D printed structure prevents deformation during curing.

The invention changes the physical and chemical parameters of the polymeric composite by incorporating high-hardness abrasive particles into the polymer matrix during 3D printing. This parameter modification transforms the material from having high wear rate to having enhanced durability and metal-honing capability, while maintaining the ease of manufacture advantage of polymeric materials.

The patent segments the abrasive tool into multiple functional layers with different abrasive particle sizes and types, where outer layers can be worn and replaced or resurfaced while preserving the underlying structure. The 3D printed modular design allows for selective replacement of worn abrasive layers without discarding the entire tool, extending overall tool lifetime while maintaining high cutting performance.

The invention enables the discarded/worn abrasive surface to be recovered through resurfacing operations on the 3D printed structure. The rigid printed body can be machined or ground to restore the abrasive surface, allowing the tool to be reused multiple times without replacing the entire tool, thus extending duration of action.

The patent transitions from a single-layer two-dimensional abrasive surface to a multi-layer three-dimensional abrasive structure. Each layer can be optimized with different abrasive particle sizes, shapes, and binding characteristics, creating a stepped or zoned abrasive surface that extends tool life by providing multiple functional zones for different stages of sharpening or honing operations.

The invention segments the abrasive tool into multiple layers with distinct functional characteristics. Inner layers can contain coarser abrasives for rapid material removal while outer layers contain finer abrasives for polishing, or the layers can be designed to wear at different rates to expose fresh abrasive surfaces, thereby extending the overall tool lifetime without significantly increasing manufacturing complexity.