Reference Feature Machining for Hybrid Additive Workpieces

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Solution Overview

Problem

Subtractive manufacturing processes are labor-intensive and limited in geometry, as they require loading and unloading of materials and have constraints on the geometries that can be economically manufactured, particularly when trying to achieve precise critical-to-quality features.

Innovation Solution

An automated manufacturing system that uses a machine-learning model to generate a graphical representation of a discrete object from an additively manufactured body, identifying critical-to-quality features and creating reference features to facilitate precise location and machining of the object within a subtractive manufacturing device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If subtractive manufacturing is used to achieve precise critical-to-quality features, then manufacturing precision is improved, but labor intensity increases and productivity decreases

Engineering Contradiction:

Improveprecision of critical featuresVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system performs preliminary identification of critical-to-quality features and automatic generation of reference features before the subtractive manufacturing process. This preliminary action enables automated setup and reduces manual labor during actual machining, thereby improving both precision and productivity

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manufacturing system uses machine-learning models to automatically identify critical features and generate reference features without human intervention. The system serves itself by autonomously determining machining parameters and setup requirements, reducing labor intensity while maintaining high precision

Inventive Principle:

Principle #25Self-service

2Ease of manufacture

If traditional subtractive manufacturing is used, then manufacturing process is simple, but geometric flexibility is limited

Engineering Contradiction:

Improvesimplicity of manufacturing processVSAvoidgeometric flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The system merges additive manufacturing capabilities with traditional subtractive manufacturing processes. Additive manufacturing provides geometric flexibility for complex shapes, while subtractive manufacturing ensures precision for critical features. This combination resolves the contradiction by maintaining process simplicity while enhancing geometric versatility

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system applies different manufacturing qualities to different parts of the same component. Critical-to-quality features receive high-precision subtractive manufacturing treatment, while non-critical areas utilize the geometric flexibility of additive manufacturing. This local differentiation allows the system to achieve complex geometries without compromising precision where needed

Inventive Principle:

Principle #3Local quality

3Ease of operation

If manual loading and unloading of materials is performed, then ease of operation is maintained, but labor intensity increases and productivity decreases

Engineering Contradiction:

Improveoperational simplicityVSAvoidmanufacturing output rate

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system replaces manual mechanical operations (loading and unloading) with automated computational processes. Machine-learning models automatically determine setup requirements and generate reference features, substituting human manual labor with intelligent automation. This maintains ease of operation through user-friendly interfaces while dramatically increasing productivity through automated processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11809162B2Methods and software for manufacturing a discrete object from an additively manufactured body of material including a precursor to a discrete object and a reference feature(s)

Publication Date: 2023.11.07 PROTO LABS INC

AI summary

An automated manufacturing system for generating a graphical representation of a discrete object to be manufactured from an additively manufactured body of material. Reference feature is used to place the precursor at a subtractive manufacturing machine; the reference feature may be based on a locating feature at the subtractive manufacturing machine. Manufacturing reference feature is accomplished by automatedly detecting one or more critical-to-quality features and manufacturing the reference feature based on the one or more detected critical-to-quality features.