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> There are machines out there today for smaller parts that will use wire deposition like this to build the bulk rough outline of the part then machine away the
by Robotbeat 8y ago
> There are machines out there today for smaller parts that will use wire deposition like this to build the bulk rough outline of the part then machine away the rough outer layer for a precision part.
Right, so all you're really saving is the first rough cut, which is normally pretty fast anyway. (And the chips can be recycled.) But now you also have to live with the material properties of welds, instead of a high quality, grain-oriented piece of forging stock. And you also have to move the part from one machine to another, then re-register it (dial it in to make sure the build is oriented correctly in the CNC machine's coordinate system). Not as bad for the hybrid machines which can do both operations, but still not great.
Back to this bridge: Without post-processing by grinding/sanding/smoothing, you're reducing the material strength due to increased localized stress concentrations. This doesn't matter much in stiffness-dominated structures, but significantly reduces the performance for strength-dominated structures and structures which experience a lot of cyclical loading.
I just don't think this is terribly scalable. Neat art project, though.
EDIT:If you want to automate things, I think it probably makes more sense to automate using more conventional building methods... Cut standard beams to size, place and weld automagically, etc. It'd be much faster..... Like this: https://www.youtube.com/watch?v=rD9__jheNLg https://www.youtube.com/watch?v=rD9__jheNLg
- rtkwe 8y agoYou don't have the move machines actually, as of about 3 years ago there are machines that'll do both in a single machine. [0] On top of that though moving from one machine to another really isn't the end of the world especially if you're able to setup the process right, like putting all the 3D printed parts onto a standard sized base plate that you can easily index off of. By bulk rough outline I mean they're basically just machining off the outer millimeter at most to smooth out the surface. It actually can save a lot of material as the size of the part increases because unless you're taking cast/forged pieces then milling them down to tighter tolerances the initial work piece will be the smallest bounding cube/rectangle or cylinder that'll fit the part which for some things is a LOT of waste. And yeah they will be slightly weaker than the same piece made out of a forged piece but that can be mitigated by part design and some annealing either after the milling or between printing and machining. [0] https://www.youtube.com/watch?v=oaIOrQi2HLM https://www.youtube.com/watch?v=oaIOrQi2HLM