Laser Sintering Reference Plate with Recessed Inserts

Solution Overview

Problem

The existing laser sintering method for producing complex mould pieces, such as those for tyres, is inefficient due to longer and more expensive cycle times compared to conventional machining, necessitating a hybrid approach to optimize production costs and precision.

Innovation Solution

A reference plate with recesses for metal inserts is used, allowing the first part of the piece to be manufactured via conventional machining and the second part via laser sintering, with the laser melting the inserts to create a strong joint between the two parts, enabling a monobloc final piece with reduced production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the entire piece is produced by laser sintering, then complex shapes can be manufactured, but production cycle time increases and costs increase

Engineering Contradiction:

Improvecomplex shape manufacturing capabilityVSAvoidproduction cycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The piece is divided into two distinct parts: a first part with simple geometries suitable for conventional machining, and a second part with complex geometries requiring laser sintering. This segmentation allows each part to be manufactured using the most appropriate process, optimizing both precision and productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first part of the piece is pre-manufactured using conventional machining methods before the laser sintering process begins. This preliminary action reduces the overall production cycle time by eliminating the need to laser sinter the entire piece, while still achieving the final complex geometry when combined with the second part.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If the entire piece is produced by laser sintering, then complex shapes can be manufactured, but manufacturing costs increase

Engineering Contradiction:

Improvecomplex shape manufacturing capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The piece is divided into two distinct parts: a first part with simple geometries suitable for conventional machining, and a second part with complex geometries requiring laser sintering. This segmentation allows each part to be manufactured using the most appropriate process, optimizing both precision and productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first part of the piece is pre-manufactured using conventional machining methods before the laser sintering process begins. This preliminary action reduces the overall production cycle time by eliminating the need to laser sinter the entire piece, while still achieving the final complex geometry when combined with the second part.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If conventional machining is used for the first part, then production costs are reduced, but the joint between parts requires additional cutting operations

Engineering Contradiction:

Improvemanufacturing costVSAvoidnumber of additional operations

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The separation line between the first and second parts is strategically positioned to coincide with the final cutting operation required for detaching the piece from the reference plate. This merging of operations eliminates the need for additional cutting steps, as the same cut that separates the piece from the plate also separates the first and second parts.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cutting operation that detaches the piece from the reference plate simultaneously serves the dual purpose of separating the first and second parts. This self-service approach eliminates redundant operations, reducing both device complexity and manufacturing costs.

Inventive Principle:

Principle #25Self-service

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

This method allows for the production of complex mould pieces with improved precision and reduced costs by utilizing conventional machining for simpler parts and laser sintering for complex parts, achieving a strong joint and eliminating the need for additional cutting operations.

Implementation Method 1

a laser source, the light power of which is capable of selectively melting successive layers of metal powders

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

the first metal powder layer is selectively melted with the aid of the beam coming from the laser source

Methodology Applied

Scientific EffectSelective laser melting: Selective Laser Sintering

Implementation Method 3

the first metal powder layer is selectively melted with the aid of the beam coming from the laser source, on the metal powder surface in contact with the heads of the inserts, so as to bond the head of each of the inserts to the rest of each of the objects to be manufactured

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS9358611B2Supporting plate for a laser sintering device and enhanced sintering method

Publication Date: 2016.06.07 MICHELIN & CO (CIE GEN DES ESTAB MICHELIN)

AI summary

Sintering device comprising a laser source, the light power of which is capable of selectively melting successive layers of metal powders, and a reference plate on which the first metal powder layer is deposited and which serves as a base for the construction of an object, characterized in that the said plate comprises one or more recesses, the shape of which is determined so as to make the said recesses capable of receiving inserts of a given shape.