Support Structure Removal Toolpaths for Hybrid Additive CNC Machining
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Solution Overview
Problem
Existing subtractive manufacturing processes lack efficient methods for automatically removing support structures from parts, often requiring manual intervention and lacking direct communication with additive manufacturing components.
Innovation Solution
A system and method that integrate additive and subtractive manufacturing components within a computer-aided manufacturing (CAM) environment, utilizing a processor to generate a subtractive tool path based on data from additive manufacturing processes, including contact lines and geometry, to automatically remove support structures using CNC machine tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual intervention is used to remove support structures, then flexibility and adaptability are maintained, but productivity and manufacturing efficiency deteriorate
Solution Approach 1:
The system enables self-service automation by having the subtractive manufacturing component automatically receive and process support structure data from the additive manufacturing component. The processor autonomously generates tool paths and validates them without requiring manual programming or intervention, allowing the system to service itself and achieve high productivity while maintaining full automation.
2Manufacturing precision
If integrated data communication between additive and subtractive components is implemented, then manufacturing precision and automation are improved, but device complexity increases
Solution Approach 1:
The system merges the additive manufacturing component and subtractive manufacturing component into a unified integrated system through a central processor. The processor receives support structure data from the additive component and automatically generates and validates tool paths for the subtractive component, combining multiple manufacturing functions into one cohesive system that improves precision while managing complexity through centralized control.
Solution Approach 2:
The system implements feedback mechanisms where the processor continuously validates generated tool paths against the original support structure data and geometry information. This feedback loop ensures manufacturing precision by verifying that the subtractive removal process will accurately eliminate only the intended support structures without affecting the final part geometry, while the automated nature of this validation manages system complexity.
3Productivity
If automated tool path generation is used, then productivity and consistency are improved, but reliability and risk of errors increase
Solution Approach 1:
The system performs preliminary action by generating and validating tool paths before actual subtractive manufacturing begins. The processor creates the tool path based on support structure contact lines and geometry data, then validates it against collision constraints and manufacturing parameters in advance. This preliminary validation ensures reliability by catching potential errors before they affect the actual part production, while maintaining high productivity through automated processing.
Solution Approach 2:
The validation component provides continuous feedback during tool path generation by checking for collisions, accessibility issues, and geometric conflicts. This feedback mechanism ensures reliability by identifying and correcting potential errors in the automated tool path before execution, while the automated nature of this validation maintains high productivity without requiring manual review of every tool path.
Data Source
AI summary
Systems and methods including an additive component; a subtractive component; and a processor configured to: receive a contact line associated with a support structure from the additive component; receive geometry associated with an orientation from the additive component; receive data associated with a tool from the subtractive component; generate a subtractive tool path based on the received contact line, the received data associated with the tool, and the received geometry; transmit the generated subtractive tool path to the analysis component for processing tool path validation; and validate, by the analysis component, the tool path based on output from a simulation component to determine whether removal of the support structure from a part is successfully computed by the subtractive component.