Modular Precision Mold Assembly for Large High-Tolerance 3D Components
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Solution Overview
Problem
Existing additive manufacturing (AM) technologies face challenges in producing large-sized, high-precision components due to high costs, slow speeds, internal stress accumulation, and cumulative geometric errors, especially in fields like aerospace and precision molds.
Innovation Solution
The method decomposes the manufacturing process into mold unit manufacturing and assembly, involving precision machining and stacking of modular mold units, allowing for independent error control and low-cost production of complex components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If direct metal AM technologies (SLM/EBM) are used to manufacture large-sized components, then high-performance metal components can be produced, but internal stress accumulation and warping deformation occur due to repeated thermal cycles, making it hard to control final dimensional precision
Solution Approach 1:
The patent divides the large-sized component into multiple small-sized sub-components that can be manufactured independently using direct metal AM. Each sub-component is produced separately to avoid cumulative thermal stress and deformation, then assembled into the final large-scale structure. This segmentation approach resolves the contradiction by maintaining high performance through AM while controlling dimensional precision through distributed manufacturing.
Solution Approach 2:
The patent introduces modular fixture units as intermediary elements that facilitate precise assembly of the segmented sub-components. These fixtures provide standardized interfaces and positioning features that ensure accurate relative positioning during assembly, thereby maintaining overall dimensional precision while enabling the benefits of segmented manufacturing.
2Ease of manufacture
If existing indirect AM methods with continuous integrated stacking are used, then cost is reduced, but minor errors accumulate layer by layer, resulting in worse final geometric tolerance for larger components
Solution Approach 1:
The patent segments the manufacturing process into independent modular units, each producing a small-sized sub-component with controlled geometric tolerance. By breaking down the continuous stacking process into discrete modular operations, error accumulation is prevented while maintaining cost-effectiveness through standardized modular fixtures and processes.
Solution Approach 2:
The patent performs preliminary precision machining on each modular sub-component before assembly. This preliminary action ensures that each unit meets strict geometric tolerance requirements independently, preventing error accumulation during the final assembly process while maintaining overall manufacturing efficiency and cost-effectiveness.
3Length of stationary object
If direct metal AM is used for large-sized components, then component size is achieved, but manufacturing speed is slow and equipment costs are high
Solution Approach 1:
The patent segments the large-sized component into multiple small sub-components that can be manufactured in parallel using multiple AM machines or multiple build chambers. This segmentation enables simultaneous production of multiple units, significantly increasing overall manufacturing speed and productivity while maintaining the capability to produce large-scale final assemblies.
4Adaptability or versatility
If direct metal AM is used for complex internal structures, then design freedom is achieved, but raw material costs and equipment costs increase significantly
Solution Approach 1:
The patent segments complex internal structures into multiple smaller sub-components, each with simplified geometry that can be manufactured more efficiently. This segmentation reduces the complexity penalty in material usage and equipment requirements while preserving the overall complex functionality through intelligent design and assembly of the segmented parts.
Data Source
AI summary
The present disclosure belongs to the technical field of additive manufacturing (AM), and specifically relates to an AM method based on modular precision mold units. The method includes: slicing a digital model of a target three-dimensional (3D) component; manufacturing separated mold unit blanks, each including a sacrificial material pattern layer and an encapsulating mold material layer; performing precision machining; forming an integrated combined mold through stacking; removing a sacrificial material to form a cavity; injecting a material; and removing a mold after curing of the material to obtain a target component. Alternatively, the method includes: acquiring a model slice; manufacturing temporary mold units, each including a negative pattern; directly filling a final component material; performing precision machining; stacking; implementing curing and connection to form an integrated whole; and removing a temporary mold to obtain a target component. The method of the present disclosure eliminates error accumulation through modular precision machining, enabling low-cost and efficient manufacturing of large-sized, high-precision, and complex structural components.