Methods of subtractively manufacturing a plurality of discrete objects from a single workpiece using a removable fixating material

• US 10,556,309 B1
• Filed: 03/23/2017
• Issued: 02/11/2020
• Est. Priority Date: 03/24/2016
• Status: Active Grant

• Current Assignee: Rapid Manufacturing Group LLC (Proto Labs, Inc.)
• Original Assignee: Proto Labs, Inc.
• Inventors: Jacobs, II, James L., Stahl, Chris
• Primary Examiner(s): Wilensky, Moshe
• Assistant Examiner(s): Cook, Kyle A
• Application Number:
  US15/467,111
• Time in Patent Office: 1,055 Days
• CPC Class Codes: B23C 2220/12 Cutting off, i.e. producing multiple discrete components from a single piece of material
• CPC Class Codes: B23C 3/10 Relieving by milling
• CPC Class Codes: B23P 13/00 Making metal objects by operations essentially involving machining but not covered by a single other subclass making specific objects B23P15/00
• CPC Class Codes: B23Q 3/061 adapted for holding a plurality of workpieces
• CPC Class Codes: B23Q 3/086 using a solidifying liquid, e.g. with freezing, setting or hardening means
• CPC Class Codes: B29C 65/70 by moulding using a particular moulding technique, see the relevant technique , e.g. by injection B29C45/14467
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 2219/45145 Milling
• CPC Class Codes: G05B 2219/49038 Support help, grid between support and prototype, separate easily

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, valleys are formed in a workpiece between adjacent partially formed objects so that interconnecting portions remain to interconnect the partially formed objects. Then, the removable fixating material is installed in the valleys, and once the removable fixating material has hardened, the workpiece is further processed to at least remove the interconnecting portions. In some embodiments, a mold is used to install the removable fixating material into the workpiece. In some embodiments, a prefabricated temporary frame is used for installing the removable fixating material into the workpiece. In some embodiments, a temporary frame is formed from the workpiece along with the plurality of objects during manufacturing.

Claims

1. 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 having a first side and a second side spaced from the first side, wherein the discrete objects are defined by through-spaces in the body of material extending from the first side to the second side after performing the method, the method comprising:

forming, by subtractive manufacturing, valleys 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 that interconnect the plurality of objects to one another, wherein the valleys form portions of the through spaces, wherein the forming of the valleys and interconnecting portions transforms the body of material into a workpiece of interconnected structures comprising precursors to the discrete objects;

locating a temporary frame laterally surrounding an object region of the body from which all of the discrete objects will be manufactured;

installing a removable fixating material into the valleys so as to laterally surround the discrete objects and be in contact with the temporary frame so as to form a stabilized workpiece;

after the fixating material has hardened, removing, using subtractive manufacturing, the interconnecting portions of the stabilized workpiece; and

after removing the interconnecting portions, removing the removable fixating material so as to liberate the plurality of objects from one another.

2. A method according to claim 1, wherein locating the temporary frame around the body of material includes providing a prefabricated frame separate from the body of material as the temporary frame, the temporary frame having a plurality of features designed and configured to receive the removable fixating material and thereby form a mechanical interlock between the temporary frame and the workpiece of interconnected structures.

3. A method according to claim 1 further comprising, forming by subtractive manufacturing, valleys in the body of material on the second side of the body of material.

4. The method according to claim 1, wherein installing the removable fixating material includes installing the removable fixating material so that the object region is stabilized relative to the temporary frame.

5. A method according to claim 1, wherein locating the temporary frame around the body of material includes providing a prefabricated support frame separate from the body of material as the temporary frame, wherein the temporary frame includes at least one reference feature designed, configured, and located for precisely locating the stabilized workpiece relative to a subtractive manufacturing machine.

6. A method according to claim 5, the method further comprising removing a layer from the second side of the body of material so as to define a planar surface across the entirety of the object regions, wherein the removing of the layer includes removing the interconnecting portions.

7. A method according to claim 1, further comprising:

subtractively manufacturing the temporary frame from the body of material.

8. A method according to claim 7, wherein subtractively manufacturing the temporary frame includes subtractively manufacturing at least one datum feature designed, configured, and located for precisely locating the stabilized workpiece relative to a subtractive manufacturing machine.

9. A method according to claim 7, wherein subtractively manufacturing the temporary frame from the body of material includes subtractively manufacturing the temporary frame contemporaneously with subtractively manufacturing the workpiece of interconnected structures.

10. A method according to claim 7, wherein subtractively manufacturing the temporary frame includes subtractively manufacturing a plurality of features designed and configured to receive the removable fixating material and thereby form a mechanical interlock between the temporary frame and the workpiece of interconnected structures.