Layered Mold Construction Using Cut Sheets and Fastened Sections
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Solution Overview
Problem
The existing methods for producing metal molds, such as aluminum molds, are inefficient due to the need for significant material removal and machining time, especially for large or complex designs, which increases costs and reduces their suitability for long-term production.
Innovation Solution
A method involving layering techniques using a CNC router or material cutting machine to create sections from sheet materials, which are then assembled and secured with fasteners, adhesives, or other means to form a mold, allowing for reduced machining and efficient channel creation for coolant or heating systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional subtractive manufacturing is used to produce aluminum molds from solid blocks, then the molds can be produced with complete structural integrity, but significant material removal time and machining cost increase
Solution Approach 1:
The mold is divided into multiple layers that are manufactured separately and then stacked together. Each layer is cut from sheet material rather than machining from a solid block, dramatically reducing material removal time while maintaining structural integrity through the stacking and fastening of layers
Solution Approach 2:
The manufacturing approach transitions from three-dimensional subtractive machining to a two-dimensional layer-by-layer construction method. Sheets of material are cut in 2D and then stacked to form the 3D mold structure, eliminating the need to machine away large volumes of material from a solid block
2Productivity
If internal channels are machined into solid block aluminum molds, then coolant circulation is enabled, but specialized equipment and significant machining time are required
Solution Approach 1:
Internal channels are created by incorporating channel structures into individual layer sheets before stacking. Each layer can have pre-formed channel pathways that align when stacked, eliminating the need for complex 3D channel machining and allowing standard cutting equipment to be used
Solution Approach 2:
Channel pathways are prepared in advance within the flat sheet material before the layers are stacked. This preliminary formation of channels in 2D sheets is much simpler than creating 3D channels through solid block machining, and the channels are already positioned and aligned before assembly
3Ease of manufacture
If large blocks of aluminum are used for mold production, then structural strength is ensured, but material cost and machining time increase significantly
Solution Approach 1:
The mold is constructed as a composite structure with multiple material layers (different sheet materials) fastened together. This composite construction provides the necessary structural strength while using less total material than a solid aluminum block, reducing both material cost and machining requirements
Solution Approach 2:
The patent employs domed or curved support structures between layers to distribute loads and enhance structural strength. These curved geometric features provide mechanical reinforcement without requiring excessive material, maintaining strength while reducing overall material usage compared to solid blocks
Data Source
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AI summary
A method of manufacturing a part (20) using a cutting machine (11) includes placing a non-porous sheet (12) on a surface of a material cutting machine (12), removing material from the non-porous sheet (12) to form a plurality of sections (24) of the part (20), and while the non-porous sheet (12) is present on the material cutting machine (11), forming fastening holes (13) within the sections (24). The method further includes removing the sections (24) from a remainder of the sheet (12), placing the sections (24) together such that each section (24) of the part (20) abuts another section (24), and inserting fasteners (34) through the fastening holes (13) of the sections (24).