Mold-Free 3D Printed Diamond Abrasive Tools
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Solution Overview
Problem
The existing manufacturing of diamond tools and wheels is labor-intensive and costly due to the use of expensive molds that wear rapidly from abrasive processes, requiring multiple machining steps and high-value materials.
Innovation Solution
3D printing technology is used to create diamond tools and wheels without molds, employing resin bonded super abrasive tools with diamond abrasive grit mixed in a curable binder material, allowing for the direct deposition of the abrasive article using liquid 3D light-cured solutions or other 3D printing methods, such as filament or powder-based processes, to reduce labor and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mold-based manufacturing is used for diamond tools, then the mechanical properties and precision can be maintained, but the manufacturing cost and labor intensity increase significantly
Solution Approach 1:
The patent uses 3D digital printing to create a digital copy or replica of the diamond tool directly from digital models, eliminating the need for physical molds. This digital manufacturing approach maintains precision while reducing the complexity and cost associated with traditional mold-making processes
Solution Approach 2:
The patent changes the manufacturing parameters from traditional mold-based physical processes to 3D digital printing processes. This includes using photo-curable resin materials that can be precisely deposited layer-by-layer under computer control, achieving high precision without requiring expensive physical molds
2Strength
If traditional mold-based manufacturing is used for diamond tools, then the required mechanical properties can be achieved, but the manufacturing time and labor intensity increase
Solution Approach 1:
The 3D digital printing process creates tools directly from digital models, eliminating multiple traditional machining steps. The photo-curable resin is deposited and cured layer-by-layer in a single integrated process, significantly reducing manufacturing time while maintaining the required mechanical properties through controlled material deposition and curing parameters
Solution Approach 2:
The patent combines multiple manufacturing operations into a single 3D printing process. The deposition of photo-curable resin, UV irradiation for curing, and tool formation are merged into one continuous automated process, eliminating the need for separate machining, assembly, and finishing operations required in traditional manufacturing
3Ease of manufacture
If expensive molds are used for diamond tool manufacturing, then the initial production can proceed, but the molds wear rapidly due to abrasive processes
Solution Approach 1:
Instead of using physical molds that are subjected to abrasive wear, the patent creates digital copies that are manufactured on-demand through 3D printing. The digital model can be reused indefinitely without degradation, and each tool is manufactured fresh through digital deposition, eliminating the wear problem entirely
Solution Approach 2:
The patent employs disposable or replaceable tool elements that are manufactured through 3D printing. Rather than investing in expensive long-lived molds that wear out, the system uses affordable digital models to create tools as needed, with the digital template itself having essentially infinite lifespan
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 labor costs, improves productivity, and minimizes scrap material, while maintaining the desired mechanical properties of the diamond tools, enabling efficient production of high-quality abrasive articles like polishing pads and rotary tools.
Implementation Method 1
The liquid resin is mixed with effective amounts of the super abrasive material and secondary fillers, and they are co-deposited and cured by printer during the 3D printing process
Data Source
AI summary
A resin bonded super abrasive tool. The tool is manufactured using a liquid 3D light cured solution printer (3D printing which uses a liquid resin super abrasive and secondary fillers). The liquid resin is mixed with effective amounts of the super abrasive material and secondary fillers, and they are co-deposited and cured by printer during the 3D printing process.