Layer Segment Connections for Additive Parts With Internal Channels
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Solution Overview
Problem
Traditional additive manufacturing methods for large, complex parts like molds and tooling made from materials like aluminum are inefficient due to the need for significant material removal and machining time, especially for internal channels, which increases cost and complexity.
Innovation Solution
A method involving cutting and shaping layer segments from sheets to form complementary ends and using connecting devices with tapers to achieve tight connections between segments, allowing for efficient assembly and integration of internal channels without extensive machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional subtractive manufacturing is used to produce large parts like molds and tooling, then the parts can be made from solid blocks of material, but significant material removal and machining time are required, increasing cost and complexity
Solution Approach 1:
The patent divides the manufacturing process into discrete layers, where each layer is formed by cutting and assembling separate segments from sheets of material. This segmentation allows each layer to be manufactured independently and assembled, eliminating the need to machine entire large parts from solid blocks and significantly reducing machining time while maintaining geometric accuracy.
Solution Approach 2:
The patent performs preliminary actions by pre-cutting and pre-shaping individual layer segments before assembly. Complementary shapes are formed on mating surfaces of segments, and connecting devices are prepared in advance, allowing for rapid assembly without extensive final machining operations.
2Ease of manufacture
If internal channels are machined into solid blocks for tooling applications, then the channels can be created, but significant time and specialized equipment are required, further increasing build time and cost
Solution Approach 1:
The patent segments the tooling into multiple layers, allowing internal channels to be formed as continuous pathways through the stacked segments. This eliminates the need for complex drilling and routing operations in solid blocks, as channels are created by aligning and connecting corresponding features in each layer during assembly.
Solution Approach 2:
The patent transitions from three-dimensional machining of solid blocks to a layered assembly approach, adding the dimension of stacking. This allows channels to be formed by aligning features across multiple layers in the vertical dimension, simplifying manufacturing and eliminating the need for specialized equipment required for complex 3D channel routing.
3Loss of substance
If layer segments are assembled to form parts, then material waste and machining time are reduced, but achieving tight connections between segments becomes challenging
Solution Approach 1:
The patent employs asymmetric complementary shapes on mating surfaces of layer segments, including tapered connecting devices that create interference fits. The asymmetric geometry ensures precise alignment and tight connections between segments, preventing gaps and maintaining manufacturing precision while preserving the material efficiency of the layered approach.
Solution Approach 2:
The patent introduces connecting devices as intermediary elements between layer segments. These connecting devices feature complementary shapes that mate with corresponding features on adjacent segments, acting as mediators to achieve tight connections and precise alignment without requiring direct contact between segment surfaces.
4Productivity
If aluminum molds are used for prototyping and short run production, then cost and production time can be reduced, but they are not suitable for long-term production applications
Solution Approach 1:
The patent segments the mold into replaceable layers, allowing individual layers to be worn or damaged without compromising the entire mold. This segmentation enables selective replacement of worn layers, extending the overall mold life and improving reliability for long-term production while maintaining the productivity benefits of aluminum construction.
Solution Approach 2:
The patent implements a strategy where worn or damaged layer segments can be discarded and replaced with new segments, while the remaining intact layers are retained and reused. This approach maximizes the utilization of each aluminum mold, extending its service life for long-term production applications while maintaining cost-effectiveness.
Data Source
AI summary
A system for manufacturing a part with a plurality of segments, the system including a machining apparatus configured to receive material, and a controller configurable to generate commands to control the machining apparatus. The controller being configurable to cause the machining apparatus to form a plurality of segments from material, cause the machining apparatus to form complementary shapes in ends of two or more segments of the plurality of segments, and cause the machining apparatus to form openings in the ends of the two or more segments.