Laser Subtraction of MIM Blanks for Custom Watch Components
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Solution Overview
Problem
Traditional methods for manufacturing metal components in watches, such as forging and stamping, are inefficient and require extensive post-processing, limiting the ability to create diverse designs without significant tooling investments.
Innovation Solution
A Metal Injection Molding (MIM) process combined with laser subtraction and CNC milling is used to form metal component parts in a non-hardened state, allowing for interim shapes and geometries to be customized before sintering, thereby enabling production of multiple designs from a single injection mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional forging and stamping methods are used to manufacture metal components, then the components can be produced with established processes, but the manufacturing efficiency is low and extensive post-processing is required
Solution Approach 1:
The MIM process performs preliminary shaping of metal components during the injection molding stage, creating near-net-shape parts that require minimal post-processing. The laser subtraction process then removes only the necessary excess material to achieve final dimensions, dramatically reducing post-processing time compared to traditional forging and stamping methods.
Solution Approach 2:
The patent replaces traditional mechanical forging and stamping processes with a combination of MIM (which uses injection molding mechanics) and laser subtraction (which uses thermal energy instead of mechanical force). This substitution eliminates the need for extensive mechanical post-processing while achieving precise dimensional accuracy.
2Adaptability or versatility
If traditional methods are used, then manufacturing processes are well-established, but the ability to create diverse designs is limited without significant tooling investments
Solution Approach 1:
The MIM injection mold serves multiple functions: it shapes the base geometry of diverse watch components and can be reused for different designs by modifying only the laser subtraction parameters. This universal tooling approach enables design diversity without requiring separate complex tooling for each design variation.
Solution Approach 2:
The patent achieves design diversity by changing laser subtraction parameters (power, speed, pattern, duration) rather than changing the physical injection mold. This allows the same MIM blank to be transformed into different watch components through parameter modification, significantly reducing tooling complexity while maintaining high adaptability.
3Productivity
If MIM blanks are formed to specific final shapes, then injection molding is efficient, but post-process cutting and material removal is minimized
Solution Approach 1:
The MIM process performs preliminary shaping to create blanks with geometry close to the final shape, minimizing the amount of material that needs to be removed later. The laser subtraction process then removes only the necessary excess material, reducing overall material loss while maintaining injection molding efficiency.
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 method reduces tooling costs and lead times, enables rapid customization of watch designs, and achieves precise, intricate features at a lower cost by leveraging the softness of the MIM blank to efficiently form complex geometries before hardening.
Implementation Method 1
the instance of the MIM blank formed for the metal component part from the injection molding tool then has at least a portion of the instance of the MIM blank subtracted through a laser subtraction process
Implementation Method 2
the instance of the MIM blank for that metal component part then went through a sintering process at a sinter station to then harden the metal component part to a finished shape and geometry
Data Source
AI summary
Types of metal component parts including a casing, a bezel, a buckle, parts for a watch band, etc. are made with the Metal Injection Molding (MIM) process. Each type of metal component part can be derived from an instance of a MIM blank corresponding to that particular type of metal component part formed from its corresponding injection molding tool. The MIM blank formed for the metal component part from the injection molding tool then has a portion of the MIM blank subtracted through a laser subtraction process to form an interim shape and geometry of the instance of the metal component part. The laser subtraction process is applied to the instance of the MIM blank for the metal component part when the instance of the MIM blank has not yet been sintered and hardened to a finished shape and geometry for that metal component part for the watch design.