Method and system for creating additive parts
AssigneeThermwood Corporation
InventorsKenneth J. Susnjara, Lawrence S. Epplin
Life of this patent
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Abstract
A method of manufacturing a part with a plurality of cut segments includes receiving a sheet of material with a machining apparatus and removing material during one or more first passes with the machining apparatus to form a plurality of segments in the sheet of material. The method also includes forming a tab by removing material during the one or more first passes with the machining apparatus for forming the segments, the tab connecting two segments within the sheet of material to each other and removing material with the machining apparatus to form joints on the segments.
Claims18
A method of manufacturing a part, the method comprising:
- forming a plurality of segments by removing material from a sheet of material during one or more first passes with a manufacturing apparatus, each segment of the plurality of segments including at least one side having a joint for attaching the segment to another segment, the joints of the plurality of segments being formed in multiple stages including:
- the one or more first passes performed with the manufacturing apparatus, during which one or more tabs are formed on at least one side without a joint of each segment of the plurality of segments while the joints are machined to an oversized form having dimensions that are larger than final dimensions;
- and
- one or more second passes with the machining apparatus, during which the one or more tabs are removed and the joints are machined while on a surface of the machining apparatus to the final dimensions, wherein the joints are machined to the final dimensions prior to removing the one or more tabs;
- assembling the plurality of segments into a plurality of layers;
- and
- stacking the plurality of layers to produce the part.
A method of manufacturing a part, the method comprising:
- forming a plurality of segments by removing material from a sheet of material during one or more first passes with a machining apparatus, each segment of the plurality of segments having a different size, shape, or dimension;
- forming a plurality of removable tabs on the plurality of segments using a tool, at least one removable tab of the plurality of removable tabs including a single curved surface, wherein forming the at least one removable tab includes:
- raising the tool while the tool is positioned at a first angle with respect to a direction of movement of the tool;
- and
- lowering the tool while the tool is positioned at a second angle with respect to the direction of movement of the tool;
- forming indicia identifying a layer of a plurality of layers on each segment of the plurality of segments;
- assembling the plurality of segments into a plurality of layers;
- and
- stacking the plurality of layers to produce the part.
A method of manufacturing a part, the method comprising:
- forming a plurality of segments by removing material from a sheet of material during one or more first passes with a machining apparatus, each segment of the plurality of segments including at least one side having a joint for attaching the segment to another segment;
- during the one or more first passes with the machining apparatus, forming one or more tabs on at least one side of each segment of the plurality of segments that does not include a joint, the joints being machined to an oversized form having dimensions that are larger than final dimensions, wherein the one or more tabs include a first tab that extends linearly and that couples a first segment of the plurality of segments to a second segment of the plurality of segments to prevent movement of the first and second segments during the one or more first passes with the machining apparatus;
- during one or more second passes with the machining apparatus, removing the tabs from the plurality of segments and machining the joints to the final dimensions while the sheet of material is present on a surface of the machining apparatus, wherein the joints are machined to the final dimensions prior to removing the one or more tabs;
- assembling the plurality of segments into a plurality of layers;
- and
- stacking the plurality of layers to produce the part.
Dependencies are inferred from the claim text.