Custom Support Structure for Machining Blind-Side Features

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Solution Overview

Problem

Automated manufacturing processes face limitations in producing parts to exact specifications, particularly due to the inability to create features on 'blind' sides of workpieces, necessitating secondary processes that are difficult to automate, leading to inefficiencies in cost and time.

Innovation Solution

A system and method for manufacturing a support structure with a recess that securely holds a discrete object for automated manufacturing, allowing precision movement and secure positioning, using a combination of additive and subtractive manufacturing methods to create a custom fixture that accommodates the workpiece's unique geometry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated manufacturing processes are used to produce parts, then productivity is improved, but manufacturing precision deteriorates due to inability to create features on blind sides

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidfeature accuracy on blind sides

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

A custom fixture acts as an intermediary between the automated manufacturing system and the workpiece. The fixture includes a recess that securely holds the workpiece in a specific orientation, enabling the automated system to access and create features on previously inaccessible blind sides without compromising precision

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of time

If automated manufacturing processes are used, then loss of time is reduced, but device complexity increases due to need for custom fixtures and secondary processes

Engineering Contradiction:

Improvemanufacturing cycle timeVSAvoidfixture and process complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The custom fixture is designed and prepared in advance with a recess that is specifically tailored to the workpiece geometry. This preliminary action enables the automated manufacturing system to directly access blind sides without requiring complex secondary processes, thereby reducing overall device complexity while maintaining time efficiency

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If secondary processes are used to create features on blind sides, then manufacturing precision is improved, but loss of time increases due to difficulty in automating these processes

Engineering Contradiction:

Improvefeature accuracyVSAvoidsecondary process time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The fixture recess creates a new spatial dimension by holding the workpiece in an inverted or reoriented position. This dimensional change allows the automated manufacturing head to access blind sides from a different angle, eliminating the need for time-consuming secondary processes while maintaining manufacturing precision

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS11249457B2Methods and systems for manufacturing a support structure

Publication Date: 2022.02.15 PROTO LABS INC

AI summary

A support structure includes a discrete object side and a recess in the discrete object side, the recess formed to mate with a fixture side of a workpiece. A method for manufacturing a support structure includes registering a discrete object model to a blank model and forming a recess in a discrete object side of the fixture blank model.