Stratified Casting Device Stratum Modification via Removable Insert
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Solution Overview
Problem
Current methods for molding complex parts using the stratoconception process are inflexible, requiring complete replacement of strata for even minor shape modifications, which is costly and inefficient.
Innovation Solution
A method for localized modification of laminated molding devices using removable inserts, where strata are designed and modified based on CAD models, allowing for precise cutting and assembly of new shapes without the need for complete stratum replacement, utilizing techniques like electro-erosion or laser cutting for insert manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complete replacement of strata is performed for shape modifications, then manufacturing precision is maintained, but loss of time and manufacturing cost increase significantly
Solution Approach 1:
The stratum is divided into a main body portion and a removable secondary portion (insert). This segmentation allows the insert to be independently replaced without replacing the entire stratum, reducing modification time while maintaining precision through the precise fit of the insert into the receiving location.
Solution Approach 2:
The secondary portion (insert) is extracted as a separate removable component from the stratum. This extraction enables the insert to be removed and replaced independently, allowing rapid shape modifications without time-consuming complete stratum replacement, while the receiving location ensures precision is maintained.
2Manufacturing precision
If complete replacement of strata is performed for shape modifications, then manufacturing precision is maintained, but manufacturing cost increases
Solution Approach 1:
By segmenting the stratum into a permanent main body and a replaceable insert, the cost of modification is reduced to only the insert manufacturing cost rather than complete stratum replacement cost, while precision is maintained through the designed fit of the insert in the receiving location.
Solution Approach 2:
The insert can be discarded or modified independently when shape changes are needed, while the main body of the stratum is recovered and reused. This significantly reduces manufacturing cost compared to complete stratum replacement, while the receiving location ensures precision is maintained.
3Adaptability or versatility
If strata are made modular for easy modification, then adaptability improves, but device complexity increases
Solution Approach 1:
The stratum is segmented into a main body and an insert with a receiving location, providing modular adaptability for shape modifications. The complexity is minimized by keeping the segmentation simple - just a receiving location and an insert - rather than complex modular interfaces, thus balancing adaptability with structural simplicity.
4Productivity
If removable inserts are used for shape modifications, then productivity improves through rapid changes, but manufacturing precision may be compromised
Solution Approach 1:
The segmentation into insert and receiving location enables rapid insertion and removal for high productivity, while the precise geometric fit between the insert and receiving location ensures that manufacturing precision is maintained despite the removable nature of the insert.
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
Enables rapid and cost-effective shape changes in molding devices, allowing for efficient adaptation of prototypes and reducing the need for extensive re-manufacturing, while maintaining the integrity of the stratified structure.
Implementation Method 1
The cutting step comprises cutting by an electro-erosion metal wire
Implementation Method 2
a cutting step using at least one cutting member to remove, in the selected stratum, the secondary portion and form a receiving location for an insert
Data Source
Figure 1
Figure 2A~3B
Figure 4~7
AI summary
The method involves selecting a stratum (1) to be modified, and decomposing the selected stratum in to main portion (10) and secondary portion. A substitution insert (S) at the secondary portion is simulated, and the secondary portion is cut using a cutting unit for removing the secondary portion from the stratum and forming a reception place (E) for an insert (2) corresponding to the simulated insert (S). The insert (2) is fabricated from a generic part, whose thickness (e) is same as that of the selected stratum. The fabricated insert is implanted in the reception place. Independent claims are also included for the following: (1) a stratum for a stratified casting device (2) an insert for a stratum (3) a stratified casting device formed by stacking a set of stratums.