Layered Sheet Mold Assembly for Faster Channel Integration
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Solution Overview
Problem
Traditional methods for producing metal molds, such as aluminum, are costly and time-consuming due to the need to machine large blocks of material and create internal channels, which can be difficult to locate and require specialized equipment, limiting their suitability for long-term production and prototyping.
Innovation Solution
The method involves cutting and assembling non-porous sheet materials using a CNC router to form layered sections that can be nested for high yield, with machining to create channels and alignment features, allowing for efficient construction of molds with reduced machining time and cost, and using different materials for securing layers to manage thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large blocks of material are used to produce aluminum molds through traditional machining, then the molds can be produced with suitable strength and durability, but the production time and cost increase significantly due to extensive material removal
Solution Approach 1:
The mold is divided into multiple thin layers that are stacked together to form the complete mold structure. Each layer is cut from sheet material and then assembled with adjacent layers using fasteners, eliminating the need to machine a single large block of material and significantly reducing production time while maintaining structural integrity
Solution Approach 2:
The mold is constructed as a composite structure combining multiple materials: aluminum sheets for the mold layers, steel rods for structural support and alignment, and adhesive for bonding layers together. This composite approach provides both the strength of traditional metal molds and the manufacturing efficiency of sheet material assembly
2Reliability
If large blocks of material are used for molding, then sufficient structural integrity can be achieved, but material waste increases due to extensive removal of excess material
Solution Approach 1:
The mold design segments the structure into multiple thin layers that are stacked together. This segmentation allows the use of sheet material with minimal waste, as the layers can be cut to precise dimensions and assembled, rather than removing large amounts of material from a solid block
Solution Approach 2:
The invention transitions from three-dimensional block machining to a layered two-dimensional assembly approach. By cutting layers from sheet material and stacking them, the process achieves the desired three-dimensional mold geometry with significantly reduced material waste
3Ease of manufacture
If internal channels are machined into solid block material, then coolant or air circulation paths can be created, but the machining time and equipment requirements increase significantly
Solution Approach 1:
The internal channels are created by incorporating them into individual layers during the cutting process, rather than machining them into a solid block. This allows channels to be formed more efficiently and assembled into the final mold structure, reducing machining time and equipment requirements
Solution Approach 2:
Channels are pre-formed in the sheet material layers before assembly, allowing for easier integration into the mold structure. This preliminary action eliminates the need for complex post-assembly channel creation and reduces overall manufacturing time
4Adaptability or versatility
If traditional machining methods are used to create mold channels, then functional cooling and heating paths can be established, but the complexity of equipment and process increases
Solution Approach 1:
The mold structure is segmented into layers that can be independently designed and assembled, allowing channels to be positioned flexibly within each layer. This segmentation eliminates the need for specialized equipment to machine channels in difficult-to-reach areas, as channels can be created using standard sheet cutting processes
Solution Approach 2:
The invention moves from three-dimensional channel machining in a solid block to two-dimensional channel creation in flat sheets that are then stacked. This dimensional change provides greater flexibility in channel positioning and eliminates the need for complex specialized machining equipment
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 significantly reduces production time and cost by minimizing material waste and enabling easier integration of channels and alignment features, while managing thermal stresses through strategic layer assembly, making it suitable for both prototyping and short-run production.
Implementation Method 1
removing material from the non-porous sheet to form a plurality of sections of the mold
Implementation Method 2
inserting fasteners through the fastening holes of the sections
Implementation Method 3
using different materials for securing layers to manage thermal expansion
Data Source
AI summary
A method of manufacturing a part using a cutting machine includes placing a non-porous sheet on a surface of a material cutting machine, removing material from the non-porous sheet to form a plurality of sections of the part, and while the non-porous sheet is present on the material cutting machine, forming fastening holes within the sections. The method further includes removing the sections from a remainder of the sheet, placing the sections together such that each section of the part abuts another section, and inserting fasteners through the fastening holes of the sections.