3D Powder Bed Jetting for Complex Abrasive Articles
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Solution Overview
Problem
Conventional abrasive article manufacturing methods require specialized and expensive molds, limiting shape complexity, leading to inhomogeneous products and high labor costs, and are not suitable for producing intricate shapes with undercuts or internal structures.
Innovation Solution
The method employs 3D powder bed jetting to additively build abrasive articles by depositing layers of abrasive particles and polymer precursor particles, bonded together with a liquid binder precursor, allowing for the creation of complex shapes and reducing mold dependency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional molding methods are used to manufacture abrasive articles, then the manufacturing process is well-established and relatively simple, but the shape complexity is limited and specialized molds are required for each shape
Solution Approach 1:
The patent uses 3D digital models as virtual copies of the desired abrasive article shapes to guide the additive manufacturing process. These digital models replace the need for physical molds, allowing complex shapes to be created without corresponding complex molding tools. The digital model can be easily modified and reused for production of multiple articles.
Solution Approach 2:
The patent transitions from conventional 2D/3D molding to true 3D additive manufacturing, building articles layer by layer in the vertical dimension. This enables creation of complex internal structures, undercut features, and organic shapes that are impossible with traditional molding methods that are constrained by mold cavity geometry.
2Manufacturing precision
If specialized molds are manufactured for each abrasive article shape, then the manufacturing precision can be maintained, but the cost and lead time increase significantly
Solution Approach 1:
The patent performs preliminary digital modeling and simulation before physical production. The 3D digital model allows for virtual verification of design accuracy, toolpath generation, and process optimization beforehand, ensuring manufacturing precision is achieved without requiring time-consuming physical mold fabrication and testing.
Solution Approach 2:
The patent replaces the mechanical mold system with a digital control system that guides additive manufacturing. The precision previously achieved through精密 mold machining is now achieved through digital model accuracy and controlled material deposition, eliminating the time required for mold manufacturing while maintaining or improving shape accuracy.
3Productivity
If conventional molding is used to produce abrasive articles, then the process is established, but labor intensity is high and production flexibility is limited
Solution Approach 1:
The additive manufacturing system is highly automated and self-sufficient, requiring minimal human intervention once the digital model and process parameters are set. The system automatically deposits binder material, cures layers, and builds the entire article without manual mold handling, material loading, or post-processing operations that characterize conventional molding.
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from mold-based form transfer to digital model-guided material deposition. This parameter change enables automated control of the entire manufacturing process through software, eliminating the need for manual operations and allowing rapid reconfiguration for different product designs without physical retooling.
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 enables the production of complex abrasive articles with uniform density and improved shape accuracy, reducing production costs and labor, and allowing for the creation of shapes that were previously impossible with traditional methods.
Implementation Method 1
applying a liquid binder precursor material in predetermined regions of the layer of loose powder particles; converting the liquid binder precursor material into a temporary binder material, wherein the temporary binder material bonds to at least a portion of the polymer bond precursor particles and the abrasive particles
Implementation Method 2
converting the polymer bond precursor particles in the abrasive article preform into polymer bond particles
Data Source
Figure 1A~1D
Figure 2~3
Figure 4~6B
AI summary
Methods of making polymer bond abrasive articles and their precursors using powder bed jetting are disclosed. Polymer bond abrasive articles prepared by the method include abrasive articles having arcuate or tortuous cooling channels, unitary structured abrasive discs, abrasive segments, shaped abrasive particles, and abrasive wheels.