Segmented 3D Wax Model Assembly for Precision Investment Casting
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Solution Overview
Problem
The challenge of creating complex, large three-dimensional wax models for investment casting with high precision and minimal defects using single injection molding is significant, as it often results in defects and inefficiencies.
Innovation Solution
A computer-implemented method involving segmentation of digital three-dimensional models into segmented wax models, utilizing a knowledge corpus and artificial intelligence models to identify manufacturing processes, tolerance limits, and assembly strategies, with robotic systems to establish a production line for assembling these models, thereby reducing defects and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If single injection molding is used to create large three-dimensional wax models, then the manufacturing process is simple, but the models contain defects and have low precision
Solution Approach 1:
The patent divides a large three-dimensional wax model into multiple smaller segmented wax models. Each segment is created separately with higher precision using 3D printing technology, then assembled together using robotic systems. This segmentation approach eliminates the defects inherent in single injection molding of large models while maintaining manufacturing feasibility through modular production.
2Productivity
If segmented wax models are assembled using manual processes, then flexibility is maintained, but productivity is low and consistency is poor
Solution Approach 1:
The patent replaces manual mechanical assembly processes with robotic systems. Robots perform the assembly of segmented wax models with high speed, precision, and consistency. The robotic automation maintains the flexibility of modular assembly while dramatically increasing productivity and ensuring uniform quality across all assembled models.
3Manufacturing precision
If complex geometric shapes are created using traditional methods, then adaptability is maintained, but manufacturing precision deteriorates
Solution Approach 1:
The patent changes the manufacturing parameters by adopting 3D printing technology for creating segmented wax models. This technology enables high-precision fabrication of complex geometric shapes that would be difficult or impossible to achieve with traditional molding methods. The digital modeling and additive manufacturing processes allow for exact replication of complex geometries with superior dimensional accuracy.
Data Source
AI summary
Described are techniques for creating complex three-dimensional wax models for investment casting. A digital three-dimensional model of an object (e.g., transmission part, engine part, brake, bracket, housing, rod, gear, door handle, etc.) is analyzed. Segmented wax models to be formed from the digital three-dimensional model of the object are then identified. A production line using robots is then established for assembling the identified segmented wax models into a complete three-dimensional wax model of the object for investment casting. In this manner, complex three-dimensional wax models may be created for investment casting with less defects than creating such wax models using single injection molding.