Segmented Gyroid Structures for Subtractive Machining Access
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Solution Overview
Problem
Subtractive manufacturing of complex gyroid structures is challenging due to access issues for cutting tools, particularly in high-density structures where the cutting tool's path is obstructed by the gyroid's surface, making it difficult to achieve smooth surfaces and consistent curvature.
Innovation Solution
The method involves subdividing the gyroid structure into partial sections with shallower passages, allowing for easier subtractive manufacturing of each section as a separate unit. These sections are then assembled to form the complete gyroid structure, maintaining the desired geometric properties and surface smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If subtractive manufacturing is used to create high-density gyroid structures, then structural strength and integrity are improved, but cutting tool access is obstructed making manufacturing difficult
Solution Approach 1:
The gyroid structure is divided into multiple partial sections or unit cells that can be manufactured separately. Each section has simplified geometry with better cutting tool accessibility, while maintaining the overall gyroid configuration and structural integrity when assembled together.
Solution Approach 2:
The manufacturing approach transitions from attempting to machine the complete complex 3D gyroid structure in one piece to manufacturing multiple simplified sections that are then assembled in space, effectively solving the accessibility problem by working in multiple dimensional configurations.
2Device complexity
If traditional subtractive manufacturing methods are used on complete gyroid structures, then manufacturing complexity is reduced, but surface smoothness and curvature consistency deteriorate
Solution Approach 1:
By segmenting the gyroid structure into smaller unit cells with simpler surfaces, each section can be manufactured with higher surface precision using conventional machining tools, avoiding the accessibility issues that prevent smooth surface completion in high-density regions of complete structures.
Data Source
AI summary
A method and an article of manufacture are disclosed for creating 3-D (3-Dimensional) gyroid-based structures such as panels, parts, and components using gyroid building blocks made by subtractive manufacturing (shaping material by removing part of the material, like making a sculpture by shaving wood from a log) that may minimize or maximize heat transfer, compared with a non-gyroid similar structure and depending on application, while maintaining high structural strength and integrity with respect to the intended applications. More specifically, the method includes subtractively manufacturing a variety of basic gyroid building blocks and then attaching the building blocks together to construct larger and more complex 3-D structures while preserving smooth surfaces and same curvature, as further described below. This may not be effectively manufactured by additive manufacturing techniques.