Gyroid Building Block Assembly for Precise Subtractive Manufacturing
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Solution Overview
Problem
Existing methods, particularly additive manufacturing, struggle to produce high-quality, complex gyroid structures due to the gyroid's intricate and inaccessible contours, making it difficult for cutting tools to reach all surfaces during subtractive manufacturing.
Innovation Solution
Subtractive manufacturing is employed to create gyroid structures by subdividing the structure into partial sections, allowing for the assembly of gyroid building blocks with precise alignment and attachment to maintain consistent curvature and structural integrity, using techniques like milling and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing is used to produce gyroid structures, then manufacturing capability is improved, but manufacturing precision deteriorates due to inaccessible contours
Solution Approach 1:
The gyroid structure is divided into multiple unit cells, each of which can be manufactured separately by subtractive manufacturing processes. This segmentation allows cutting tools to access all surfaces within each unit cell while maintaining the overall gyroid geometry through precise assembly of the segmented components.
2Manufacturing precision
If subtractive manufacturing is used to create complex gyroid structures, then manufacturing precision is improved, but device complexity increases due to inaccessible contours
Solution Approach 1:
The complex gyroid structure is segmented into simpler unit cells that are easier to manufacture with traditional cutting tools. Each unit cell maintains the essential gyroid geometry while being sufficiently simple to access all surfaces, thereby reducing the overall device complexity for manufacturing purposes.
Solution Approach 2:
Unit cells serve as intermediary components between the simple manufacturable forms and the complex final gyroid structure. These intermediaries can be manufactured with high precision using conventional tools and then assembled to create the complete complex gyroid structure.
3Productivity
If additive manufacturing is used to produce gyroid structures, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
By segmenting the gyroid structure into unit cells, the patent enables parallel manufacturing of multiple identical components, improving productivity through batch production while maintaining high geometric accuracy in each segment using precision subtractive manufacturing.
Data Source
AI summary
A method and an article of manufacture are disclosed for creating 3-D (3-Dimensional) gyroid-based structures such as panels, parts, and components using gyroid building blocks made by subtractive manufacturing (shaping material by removing part of the material, like making a sculpture by shaving wood from a log) that may minimize or maximize heat transfer, compared with a non-gyroid similar structure and depending on application, while maintaining high structural strength and integrity with respect to the intended applications. More specifically, the method includes subtractively manufacturing a variety of basic gyroid building blocks and then attaching the building blocks together to construct larger and more complex 3-D structures while preserving smooth surfaces and same curvature, as further described below. This may not be effectively manufactured by additive manufacturing techniques.