Hybrid Manufacturing Planning with Interleaved Additive-Subtractive Steps
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Solution Overview
Problem
Current hybrid manufacturing approaches are limited by a two-step process that incurs significant material waste and restricts the design space, as they rely on additive manufacturing to create a near-net shape followed by subtractive processing to remove support structures.
Innovation Solution
A multi-modal hybrid manufacturing process plan is generated using a tree graph structure that interleaves additive and subtractive operations, allowing for cost-optimal production of complex parts by selecting manufacturing operations based on cost estimates and tooling capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If additive manufacturing is used to create near-net shape with support structures, then complex shapes can be achieved, but significant material waste occurs
Solution Approach 1:
The manufacturing process is segmented into multiple alternating additive and subtractive stages rather than a single two-step process. The tree graph structure divides the manufacturing plan into discrete operations that can be selectively applied to different regions of the workpiece, allowing material to be added only where needed and removed only where necessary, thereby reducing overall material waste while maintaining complex shape capability
Solution Approach 2:
Different manufacturing operations (additive or subtractive) are applied to different local regions of the workpiece based on specific requirements. The system evaluates each region's needs and selects the appropriate operation locally, allowing complex shapes to be achieved in regions where additive manufacturing is beneficial while minimizing material removal in regions where it is not needed
2Ease of manufacture
If support structures are added in additive manufacturing, then overhangs can be supported, but design space is restricted
Solution Approach 1:
Support structures are treated as temporary, extractable elements rather than permanent design constraints. The system automatically identifies and plans for the removal of support structures through subtractive operations, allowing designers to focus on the final part geometry without being constrained by additive manufacturing support requirements. The support structures are extracted in the subtractive stages, freeing up design space
Solution Approach 2:
The manufacturing approach is dynamic rather than static, alternating between additive and subtractive operations based on the current state of the workpiece and the target geometry. This dynamic approach allows the process to adapt to different design requirements at different stages, expanding the usable design space by selectively applying support structures only when and where absolutely necessary
3Manufacturing precision
If two-step hybrid manufacturing process is used, then support structures can be removed, but productivity is reduced
Solution Approach 1:
The manufacturing process maintains continuous useful action by interleaving additive and subtractive operations rather than completing all additive operations first and then all subtractive operations. This continuous alternation allows material to be added and removed in an optimized sequence, reducing total process time and improving productivity while maintaining the precision needed for support structure removal
Solution Approach 2:
Subtractive operations are planned and positioned in advance within the tree graph structure to remove support structures at optimal points during the manufacturing process. This preliminary planning allows the system to anticipate and prepare for support structure removal, integrating it smoothly into the overall process rather than treating it as a separate post-processing step, thereby improving productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the efficient and cost-effective manufacture of complex parts by optimizing the sequence of additive and subtractive operations, reducing material waste and expanding the design space available in hybrid manufacturing.
Implementation Method 1
Many forms of additive manufacturing make use of transforming matters from one state to another, such as from liquid to solid, by chemical reactions, or by heat
Implementation Method 2
Many forms of additive manufacturing make use of transforming matters from one state to another, such as from liquid to solid, by chemical reactions
Implementation Method 3
a layer of photo-sensitive polymer is jetted (similar to ink-jet printing) on a flat surface formed by the previous layer and cured into solid by ultra-violet (UV) light
Implementation Method 4
a molten string of filament is extruded and deposited by a hot-end nozzle into a sliced pattern in each layer, the molten string solidifies after exiting the hot-end nozzle
Implementation Method 5
a molten string of filament is extruded and deposited by a hot-end nozzle into a sliced pattern in each layer, the molten string solidifies after exiting the hot-end nozzle
Data Source
AI summary
The present disclosure provides techniques for determining a manufacturing plan. An example method includes obtaining an initial object definition describing an initial state of a manufacturing plan and obtaining a final object definition describing a target shape of an object to be formed through the manufacturing plan. The method also includes generating a tree comprising a plurality of nodes and edges. Each edge represents a selected manufacturing operation. The nodes include a parent node representing the initial object definition, intermediate child nodes representing an intermediate state of the object, and leaf nodes representing the target shape. The selected manufacturing operation applied at each edge may be a subtractive manufacturing (SM) operation or an additive manufacturing (AM) operation. The method also includes identifying a lowest cost manufacturing plan comprising a sequence of manufacturing operation connecting the parent node and one of the leaf nodes.