Replacement Part Manufacturing Using 3D Scans and PLM Reference Models
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Solution Overview
Problem
The challenge of obtaining replacement parts for complex assemblies, particularly in aerospace applications, arises when original suppliers cease production, leading to high costs and lengthy lead times due to the lack of digital models compatible with additive manufacturing techniques.
Innovation Solution
A method involving 3D imaging of a target part to identify suitable reference parts from a PLM database, modifying these parts using additive and subtractive manufacturing techniques to match the target's geometric and mechanical specifications, and combining different AM methods to create a replacement part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods are used to create replacement parts, then manufacturing precision can be maintained, but production time and cost increase significantly
Solution Approach 1:
The patent changes the manufacturing approach from traditional subtractive or formative methods to additive manufacturing, fundamentally altering how parts are produced. By using 3D printing technology, the system can rapidly fabricate replacement parts with complex geometries while maintaining required mechanical properties, thus reducing lead time without sacrificing precision
Solution Approach 2:
The system performs preliminary actions by creating digital models and simulations before actual manufacturing. The method includes obtaining 3D images of target parts, comparing them to reference parts in a database, and planning manufacturing steps in advance, which enables rapid production while ensuring precision requirements are met
2Manufacturing precision
If new digital models are created from scratch for additive manufacturing, then manufacturing precision can be ensured, but time and cost for model creation increase
Solution Approach 1:
The patent uses copying by obtaining 3D images of existing target parts and comparing them to reference parts in a database. Instead of creating entirely new digital models, the system copies and adapts existing reference models to match the target part geometry, significantly reducing model creation time while maintaining accuracy through image-based verification
Solution Approach 2:
The system creates a universal database of reference parts that can serve multiple purposes. A single reference part model can be used as a basis for creating replacement parts for multiple target parts with similar geometries, making the digital modeling process more efficient and reusable across different manufacturing scenarios
3Ease of manufacture
If a single additive manufacturing technique is used, then process simplicity is maintained, but adaptability to different part requirements decreases
Solution Approach 1:
The patent segments the manufacturing process into distinct steps using different additive manufacturing techniques. The method divides part fabrication into substrate creation (using first AM technique) and feature addition (using second AM technique), allowing each technique to be optimized for its specific function while maintaining overall process manageability
Solution Approach 2:
The system dynamically selects and combines different additive manufacturing techniques based on the specific requirements of each part. The manufacturing method is not fixed but adapts to the geometric and mechanical property specifications of the target part, enabling versatility while keeping the process structured and controllable
Data Source
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AI summary
A method of making a replacement part (10) includes obtaining a physical example of a target part (10) and imaging the physical example of the target part (10) to produce a 3D image of the target part (10). The 3D image of the target part (10) is compared to parts in a PLM database to identify a reference part (10-A) to use as a basis making a replacement part for the target part (10). The PLM database includes a digital model for a baseline AM technique for making the reference part (10-A). The reference part (10-A) is compared to the target part (10) to identify missing and/or extraneous features (10Δ) on the reference part (10-A). A replacement part manufacturing method for modifying the reference part (10-A) to provide missing features (10Δ) and/or to remove extraneous features to make a replacement part for the target part (10) is determined. The replacement part for the target part (10) is made using the replacement part manufacturing method.