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Method of combining metal and ceramic inserts into stereolithography components
| Details |
Inventors: O'Connor, Kurt Francis; Nohns, Dennis Carl; Chattin, William Allen;
Assignee: Delco Electronics Corporaiton (Kokomo, IN)
Primary Examiner: Tentoni; Leo B.
Assistant Examiner:
Attorney, Agent or Firm: Funke; Jimmy L.
A stereolithography process for developing a prototype part in which inserts of a non-photopolymer material are included within the resulting part so as to develop a functioning prototype part. In order to allow the inserts to be placed within the developing prototype part, a series of STL files are defined for forming the prototype part in individual sections. A non-photopolymer insert is manually positioned on one section of the developing part each time a section is formed. In order to align one section to a subsequent section, alignment structures are developed by the STL files. In order to prevent the STL files from developing supporting structures in the cavities intended for the inserts, a supporting structure file is defined for a parent design, and then later combined with the STL files. |
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DETAILED DESCRIPTION In accordance with the teachings of the present invention, a stereolithography process for developing a part is disclosed in which inserts of a non-photopolymer material are included within the resulting part.
According to one aspect of the process, parent database files, such as CAD files, are first modified to include cavities for the inserts and are then separated into a series of subpart STL files in which each subpart STL file is used to develop an individual section of the part.
The individual sections of the part are separated at locations where the non-photopolymer inserts are to be positioned.
A non-photopolymer insert is positioned on one section of the developing part each time a section is formed.
In order to align one section to a subsequent section, various alignment structures are developed by the STL files.
Further, in order to prevent support structures and bridge work from being developed in the cavities intended for the inserts, a stereolithography file is first developed from the original CAD file, and a support structure file is then created for the parent stereolithography file.
The support structure stereolithography file is then combined with each of the subpart stereolithography files.
Additional objects, advantages and features of the present invention will become apparent from the following description and appended claims taken in conjunction with the accompanying drawings.
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MEMS 
