Reference Features for Hybrid Additive-Subtractive Machining
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Solution Overview
Problem
Subtractive manufacturing processes, such as rotary-tool milling, are labor-intensive and limited in geometry, requiring frequent loading and unloading of materials and restricting the complexity of objects that can be manufactured.
Innovation Solution
An automated manufacturing system that uses additively manufactured bodies with integrated reference features to precisely locate and orient them within subtractive manufacturing devices, enabling the production of discrete objects with critical-to-quality features by combining additive and subtractive manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If subtractive manufacturing processes are used to manufacture discrete objects, then manufacturing precision of critical features can be achieved, but labor intensity increases and geometry complexity is limited
Solution Approach 1:
The patent applies preliminary action by additively manufacturing reference features and locating structures before the subtractive manufacturing process. The additive process pre-forms the body of material with integrated reference features that will be used during subtractive manufacturing, eliminating the need for manual setup and positioning operations. This preliminary preparation reduces labor intensity while maintaining the precision benefits of subtractive manufacturing for critical features.
Solution Approach 2:
The patent merges additive and subtractive manufacturing processes into a hybrid workflow. The additive process creates the near-net-shape body with integrated reference features, while the subtractive process finishes critical features requiring high precision. This combination allows automated operation with minimal manual intervention, resolving the contradiction between precision and productivity.
2Manufacturing precision
If subtractive manufacturing processes are used to manufacture discrete objects, then manufacturing precision can be maintained, but device complexity increases due to frequent loading and unloading operations
Solution Approach 1:
The additive manufacturing process preliminarily creates integrated reference features and locating structures that simplify subsequent subtractive manufacturing operations. These pre-formed features enable automated positioning and reduce the complexity of fixtures and setup procedures, allowing the subtractive process to focus solely on precision feature creation without complex loading/unloading mechanisms.
3Productivity
If additively manufactured bodies with reference features are used, then labor intensity is reduced and geometry complexity is increased, but manufacturing precision of critical features must be ensured
Solution Approach 1:
The patent combines additive and subtractive manufacturing in a hybrid process where the additive process creates the near-net-shape body with automated reference features, and the subtractive process finishes critical features requiring high precision. This merging allows automated operation (improving productivity) while maintaining the precision benefits of subtractive manufacturing for critical features through proper process integration.
Solution Approach 2:
The patent applies local quality by using different manufacturing processes for different parts of the same object. The additive process is used for the bulk material and non-critical features where high precision is less important, while the subtractive process is applied locally to critical features requiring high precision. This selective approach maintains overall productivity while ensuring critical features meet precision requirements.
4Loss of substance
If traditional subtractive manufacturing is used, then material waste is high due to loading and unloading operations, but process simplicity is maintained
Solution Approach 1:
The additive manufacturing process preliminarily creates the near-net-shape body with minimal material waste, and the integrated reference features enable automated positioning that reduces additional material loss during subtractive operations. This preliminary preparation simplifies the overall process by eliminating manual handling steps that cause material waste, while maintaining ease of manufacture through automated workflows.
Data Source
AI summary
An automated manufacturing system for manufacturing a discrete object is configured to manufacture a reference feature on a precursor to the discrete object. 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.