US 11,565,358 B2Granted

Methods of subtractively manufacturing a plurality of discrete objects from a single workpiece

AssigneeProtolabs, Inc.

InventorChristopher Stahl

Life of this patent

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Abstract

Methods involving adding a removable fixating material to a partially manufactured workpiece to stabilize a plurality of partially formed objects therein for subsequent manufacturing. In one example, a workpiece of interconnected structures is manufactured comprising precursors to the discrete objects as a function of a workpiece computer model. Manufacturing the workpiece further includes forming valleys between adjacent partially formed objects so that interconnecting portions remain to interconnect the partially formed objects. Further, the methods include removing the interconnecting portions so as to liberate the plurality of objects from one another. In some embodiments, a temporary frame is formed from the workpiece along with the plurality of objects during manufacturing.

Claims18

Dependent claims

A method of manufacturing a plurality of discrete objects, wherein each discrete object represents at least a partially completed form of at least a part of a finished product, from a body of material, wherein the discrete objects are defined by through-spaces in the body of material extending from a first side to a second side after performing the method, the method comprising:

receiving the body of material, wherein the body of material comprises the first side and the second side, and the second side is spaced from and opposite of the first side;
generating a workpiece computer model, wherein the workpiece computer model comprises a plurality of computer models of differing structures, wherein the plurality of computer models of differing structures includes a first computer model of a first type of object and a second computer model of a second type of object, and wherein the plurality of computer models of differing structures includes a computer model of a temporary frame which is selected from a library of computer models of differing temporary frames;
subtractively manufacturing a workpiece of interconnected structures comprising precursors to the discrete objects and the temporary frame as a function of the workpiece computer model, wherein generating the workpiece of interconnected structures comprises forming valleys, wherein the valleys form portions of the through-spaces, in the body of material on the first side of the body of material so as to leave interconnecting portions of the body of material, wherein the interconnecting portions interconnect the plurality of discrete objects to one another;
removing the interconnecting portions of the workpiece to create a stabilized workpiece, wherein removing the interconnecting portions of the workpiece further comprises:
removing a uniform layer having a constant thickness from the second side of the body of material to define a planar surface across the entirety of the second side of the stabilized workpiece;
and
liberating the plurality of discrete objects from one another.

4 more elements

receiving the body of material, wherein the body of material comprises the first side and the second side, and the second side is spaced from the first side;
subtractively manufacturing a workpiece of interconnected structures comprising precursors to the discrete objects and a temporary frame as a function of a workpiece computer model, wherein generating the workpiece of interconnected structures comprises forming valleys, wherein the valleys form portions of the through-spaces, in the body of material on the first side of the body of material so as to leave interconnecting portions of the body of material, wherein the interconnecting portions interconnect the plurality of discrete objects to one another, and wherein the workpiece computer model includes a computer model of the temporary frame which is selected from a library of computer models of differing temporary frames;
and
removing the interconnecting portions of the workpiece to create a stabilized workpiece, wherein removing the interconnecting portions of the workpiece further comprises:
removing a uniform layer having a constant thickness from the second side of the body of material to define a planar surface across the entirety of the second side of the stabilized workpiece;
and
liberating the plurality of discrete objects from one another.

4 more elements

Dependencies are inferred from the claim text.

Facts

Application: 16/724,512Filed 23 Dec 2019 · continuation
Priority: 24 Mar 2016
Published: US 2020/0198070 A125 Jun 2020
Granted: 31 Jan 2023
Term ends: Not estimatedThe source records don’t support an estimate.

Classification14 codes

B23Q 3/061
Work-clamping means: adapted for holding a plurality of workpieces
G05B 19/4099
Characterised by using design data to control NC machines, e.g. CAD/CAM: surface or curve machining, making three-dimensional [3D] objects, e.g.…
B23C 3/10
Milling particular work; Special milling operations; Machines therefor: relieving by milling
B23P 13/00
Making metal objects by operations essentially involving machining but not covered by

Family

Application62/312,532Us provisional application · filed 24 Mar 2016
Application15/467,111Parent of this continuation · filed 23 Mar 2017
US 2020/0198070 A1Pre-grant publication · published 25 Jun 2020
US 10,556,309 B1Parent of this continuation
US 11,565,358 B2This patent

From the US filing history. Foreign family members aren’t listed.