Automated Sheet-Based Additive Manufacturing With Micro-Milling Correction
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Solution Overview
Problem
The existing Stratoconception (REGISTERED TM) additive manufacturing method is not suitable for industrialization and automation, as it requires manual intervention and lacks a comprehensive solution for optimizing sheet distribution, cutting, and gluing processes.
Innovation Solution
A method and machine for automating the layer-by-layer manufacturing of objects using a solid/solid additive manufacturing method, which involves digital breaking down of objects into sheets, optimized distribution on a plate, calculation of cutting trajectories, micro-milling, turning, wedging, and automated gluing and positioning of sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual artisanal manufacturing is used, then ease of operation is maintained, but productivity and automation capability deteriorate
Solution Approach 1:
The manufacturing process is divided into distinct automated stages: digital slicing of the object into sheets, optimized distribution of sheets on plates, calculation of cutting trajectories, micro-milling operations, turning operations, and automated gluing/assembly. Each stage can be independently automated while maintaining operational simplicity through computer control.
Solution Approach 2:
Manual mechanical operations are replaced with computer-controlled automated systems including digital slicing software, CNC micro-milling machines, automated plate handling systems, and programmable gluing/assembly equipment. This substitution enables industrialization while maintaining ease of operation through software interfaces.
2Manufacturing precision
If calibrated plates are used to correct thickness variations, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The system performs preliminary measurement of plate thickness variations before manufacturing, then pre-calculates compensation trajectories for cutting and machining operations. This preliminary action allows the system to work with non-calibrated plates while achieving precise dimensional accuracy through software-based compensation rather than hardware calibration.
Solution Approach 2:
The system changes the parameters of the cutting and machining trajectories based on measured plate thickness variations. By dynamically adjusting tool paths and cutting parameters according to actual plate conditions, the system compensates for thickness variations without requiring calibrated plates or additional calibration equipment.
3Manufacturing precision
If joint thickness is calibrated during deposition, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system incorporates feedback mechanisms that measure actual joint thickness after deposition, then use this information to adjust subsequent gluing and assembly operations. This closed-loop feedback enables precise dimensional control while maintaining relatively simple device architecture through software-based compensation rather than complex precision deposition equipment.
4Adaptability or versatility
If 3D milling operations are performed to create drafted and undercut parts, then manufacturing capability is improved, but productivity and process complexity deteriorate
Solution Approach 1:
The system segments the manufacturing process into separate specialized operations: 2D cutting for basic sheet formation, 3D micro-milling for drafted and undercut features, and automated assembly. By dividing the process into distinct stages with dedicated equipment, the system maintains versatility for complex geometries while improving overall productivity through optimized workflow and reduced setup time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method and machine enable fully automated layer-by-layer manufacturing, eliminating manual intervention and improving dimensional accuracy by correcting defects through micro-milling after each sheet is stacked, thus facilitating the industrialization of the Stratoconception process.
Implementation Method 1
a machining table held by vacuum
Implementation Method 2
deposition of glue on said first sheet
Data Source
AI summary
A method and machine for automating the layer-by-layer manufacturing of an object according to a solid-solid additive manufacturing method, includes a vacuum table and at least one machining tool movably mounted above the table. The machine also includes a turning station having a cross member which is movable in a longitudinal direction above the table and in a vertical direction. There is a device gripping a plate mounted such that it can rotate about an axis parallel to the cross member. The machine also includes a device supporting a plate to allow the plate to be gripped on either of the two sides thereof by the device gripping the plate. There is an X and Y wedge device suitable for determining the position for, and positioning a plate, a set or a sheet.