Additive Manufacturing Obstacle Part for Capability Assessment
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Solution Overview
Problem
Designers face challenges in objectively evaluating the capabilities of additive manufacturers to produce parts with specific features and material properties, as existing methods lack standardized testing protocols to assess dimensional tolerances and material properties effectively.
Innovation Solution
The development of an additive manufacturing obstacle part with various features, including internal and external obstacles, that can be used as a template for manufacturers to test their abilities, allowing for comparison against specified specifications and evaluation of excess material removal and surface finish, among other criteria.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing processes are used to produce parts with complex features, then design versatility and complexity are improved, but manufacturing precision and dimensional tolerances deteriorate
Solution Approach 1:
The patent applies preliminary action by designing and manufacturing a master model with precise dimensions using conventional manufacturing methods before creating the additive manufacturing mold. This master model serves as a reference standard that establishes the desired dimensional tolerances and geometric accuracy, allowing the additive manufacturing process to be evaluated and adjusted against known precision benchmarks.
Solution Approach 2:
The patent uses copying by creating a physical master model that replicates the desired final part geometry with high precision, then using this master model to create the additive manufacturing mold. The master model's precise features are copied into the mold cavity, which then produces test parts that can be compared against the original specifications to assess manufacturing precision.
2Measurement precision
If standardized testing protocols are implemented to evaluate manufacturer capabilities, then measurement precision and objective evaluation are improved, but device complexity and testing procedures increase
Solution Approach 1:
The patent applies universality by designing a multi-functional master model that incorporates various test features (flat surfaces, stepped features, holes, slots, threads, radii, and surface finish variations) all in one standardized part. This single master model can evaluate multiple manufacturer capabilities simultaneously, including dimensional accuracy, geometric tolerances, surface finish quality, and material properties, thereby reducing the need for multiple separate test protocols and devices.
3Measurement precision
If comprehensive feature sets are included in test parts to assess all manufacturer abilities, then measurement completeness is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent applies merging by combining multiple test features that would traditionally require separate test parts into a single integrated master model. The master model includes flat surfaces, stepped features, holes, slots, threads, radii, and surface finish variations all in one component, allowing comprehensive evaluation of manufacturer capabilities in a single production cycle rather than requiring multiple separate test parts.
Solution Approach 2:
The master model serves multiple evaluation functions simultaneously - assessing dimensional tolerances, geometric accuracy, surface finish quality, and material properties - thereby achieving comprehensive measurement completeness through a single standardized test part that can be manufactured and evaluated in one production cycle.
Data Source
AI summary
An additive manufacturing obstacle part can comprise a base structure comprising at least one external obstacle, and at least one internal obstacle that is formed at least partially within the base structure. The at least one internal obstacle can comprise an elongated internal obstacle extending through the base structure between an inlet and an outlet formed in the base structure. The elongated internal obstacle can comprise at least one wall extending along a nonlinear path. The non-linear path can hinder travel of excess material from an additive manufacturing process along a linear path between the inlet and outlet. This can help a designer to assess an additive manufacturers ability to cleanly produce an internal feature to specifications while removing excess material resulting from the additive manufacturing process.