Layer Segment Connections for Additive Parts With Internal Channels
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Solution Overview
Problem
Traditional additive manufacturing methods face challenges in producing large, complex parts from nonporous materials like metal, particularly aluminum, due to high material waste and the difficulty in creating internal channels for temperature control, which increases production time and cost.
Innovation Solution
A method involving cutting and shaping layer segments from sheets to form complementary ends, drilling holes and slots, and using a connecting device with a tapering shape to secure the segments tightly together, allowing for efficient assembly and integration of internal channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional subtractive manufacturing is used to produce large parts from solid blocks, then the parts have high structural integrity, but significant material waste occurs and production time increases
Solution Approach 1:
The invention divides the manufacturing process into segments: cutting layers from sheets, machining individual layer segments, and assembling them together. This segmentation allows each layer to be manufactured independently and efficiently, then joined to form the complete part, reducing both material waste and overall production time compared to machining a solid block.
Solution Approach 2:
The invention transitions from three-dimensional subtractive manufacturing (machining a solid block) to a layered approach where two-dimensional sheets are cut, machined, and stacked. This dimensional change enables more efficient material utilization and reduces the need to remove large amounts of material to achieve complex geometries.
2Temperature
If internal channels are machined into solid blocks for temperature control, then temperature control is achieved, but production time and cost significantly increase
Solution Approach 1:
The manufacturing process is segmented so that channels are machined into individual layer segments separately during the layer fabrication stage, rather than attempting to machine complex three-dimensional channels through a solid block. This makes channel integration much more efficient and less time-consuming.
Solution Approach 2:
Channel creation transitions from complex three-dimensional machining in a solid block to two-dimensional channel machining in flat layers, followed by stacking. This dimensional simplification dramatically reduces the time and cost required to create temperature control channels while maintaining effectiveness.
3Loss of substance
If layer segments are assembled to form large parts, then material waste is reduced, but assembly complexity and time increase
Solution Approach 1:
Complementary shapes are machined into the layer segments in advance during the layer fabrication stage, before assembly. This preliminary action ensures that the segments will fit together precisely when assembled, reducing assembly complexity and time while maintaining the material efficiency benefits of the layered approach.
4Manufacturing precision
If complementary shapes are machined into layer segment ends, then assembly precision is improved, but machining time per layer increases
Solution Approach 1:
Rather than machining entire layer segments to final dimensions, the process machines only the critical complementary shapes at the ends of layers that are necessary for assembly. This partial action approach achieves sufficient assembly precision while minimizing the additional machining time required per layer.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A method of manufacturing a part with a plurality of cut segments includes receiving a sheet of material with a machining apparatus, removing material with the machining apparatus to form a plurality of segments (14, 15) in the sheet of material, and forming complementary shapes (38, 40) in ends of two or more segments (14, 15) of the plurality of segments. The method further includes forming slots (27, 28) in the two or more segments (14, 15), aligning the slots (27, 28) in the two or more segments (14, 15) to form a cavity, and inserting a connecting device to fill the cavity.