Replacement Part Manufacturing Using 3D Scans and Reference Models
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Solution Overview
Problem
The challenge of obtaining replacement parts for complex mechanical assemblies, particularly in aerospace applications, arises when original production models end, leading to high costs and lengthy lead times due to the lack of available digital models and suppliers, especially for Cold Start programs.
Innovation Solution
A method involving 3D imaging of a physical target part, comparison with a PLM database to identify suitable reference parts, and using additive manufacturing techniques to modify or augment these parts to match the target's specifications, including combining different AM methods for specific features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods are used for replacement parts, then parts can be produced using established processes, but the lead time and cost increase significantly when digital models are unavailable
Solution Approach 1:
The patent creates a digital copy (3D scan) of the physical target part when digital models are unavailable. This digital replica serves as a substitute for the original CAD model, enabling additive manufacturing without requiring access to original design files or tooling, thus resolving the contradiction between part availability and production time
Solution Approach 2:
The patent performs 3D scanning and digital model creation in advance before manufacturing is needed. By having the digital model ready beforehand through scanning existing parts, the system eliminates the time-consuming search for original digital models when replacement parts are urgently needed
2Reliability
If traditional manufacturing methods are used for replacement parts, then established manufacturing processes can be applied, but costs increase due to lack of available digital models and suppliers
Solution Approach 1:
The patent creates a digital copy (3D scan) of the physical target part when digital models are unavailable. This digital replica serves as a substitute for the original CAD model, enabling additive manufacturing without requiring access to original design files or tooling, thus resolving the contradiction between part availability and production time
Solution Approach 2:
The patent changes the manufacturing approach from traditional subtractive or formative methods to additive manufacturing. This parameter change enables production without original tooling or digital models, reducing costs by eliminating the need for expensive supplier qualification and tooling creation for low-volume replacement parts
3Productivity
If additive manufacturing is used to create replacement parts from 3D scans, then rapid production is enabled, but the process requires identifying and correcting missing or extraneous features in the scanned model
Solution Approach 1:
The patent implements a feedback loop where the 3D scanned model is compared against the target part specifications to identify missing or extraneous features. This feedback mechanism allows for automated detection and correction of scanning errors, maintaining high productivity while managing process complexity through systematic validation
Solution Approach 2:
The system performs self-validation by automatically comparing the scanned digital model with the known target part specifications. This self-service approach identifies discrepancies without requiring manual inspection, enabling rapid correction of missing or extraneous features while maintaining high production speed
Data Source
AI summary
A method of making a replacement part includes obtaining a physical example of a target part and imaging the physical example of the target part to produce a 3D image of the target part. The 3D image of the target part is compared to parts in a PLM database to identify a reference part to use as a basis making a replacement part for the target part. The PLM database includes a digital model for a baseline AM technique for making the reference part. The reference part is compared to the target part to identify missing and/or extraneous features on the reference part. A replacement part manufacturing method for modifying the reference part to provide missing features and/or to remove extraneous features to make a replacement part for the target part is determined. The replacement part for the target part is made using the replacement part manufacturing method.