Methods and systems for support structures in cut parts

Patent metadata

Field	Value
Publication number	US-2025387955-A1
Application number	US-202519314984-A
Country	US
Kind code	A1
Filing date	Aug 29, 2025
Priority date	Sep 25, 2023
Publication date	Dec 25, 2025
Grant date	—

Abstract

A method of manufacturing a part includes removing material with a cutting machine to form a plurality of segments, at least two of the segments including an anchoring structure, connecting two or more segments to form a first layer, and connecting two or more additional segments to form a second layer. The method also includes connecting the first layer to the second layer and connecting a support structure directly to two of the anchoring structures.

First claim

What is claimed is:

1 . A part formed by additive manufacturing, the part comprising:
a first segment including an inner surface, an outer surface, a top surface, a bottom surface, a first side, and a second side; a second segment connected to the first side of the first segment to form a first layer; a third segment connected to the top surface of the first segment, the third segment forming a portion of a second layer; and a support structure extending from the first layer to the second layer, the support structure connecting the first segment to the third segment via the inner surface of the first segment and an inner surface of the third segment.

2 . The part of claim 1 , wherein the first layer and the second layer together form a hollow interior of the part.

3 . The part of claim 1 , wherein the first layer and second layer together form a hollow interior of the part, and wherein the support structure extends within the hollow interior.

4 . The part of claim 1 , further comprising:
anchoring structures, including at least one anchoring structure formed on the first layer and at least one anchoring structure on the second layer, wherein the first layer and the second layer together form a hollow interior, and wherein the anchoring structures include protrusions that extend towards the hollow interior.

5 . The part of claim 1 , further comprising:
anchoring structures, including at least one anchoring structure formed on the first layer and at least one anchoring structure on the second layer, the anchoring structures formed on an inner surface of the first layer and the inner surface of the second layer.

6 . The part of claim 1 , further comprising:
anchoring structures, including at least one anchoring structure formed on the first layer and at least one anchoring structure on the second layer, wherein the anchoring structures include protrusions that extend toward an interior of the first layer or of the second layer.

7 . The part of claim 1 , further comprising:
anchoring structures, including at least one anchoring structure formed on the first layer and at least one anchoring structure formed on the second layer, wherein the support structure is fixed to the anchoring structures.

8 . The part of claim 1 , wherein the support structure connects the first layer to the second layer.

9 . The part of claim 1 , further comprising:
a second support structure, wherein the second support structure extends from the first segment to the second segment.

10 . The part of claim 1 , further comprising:
anchoring structures, including at least one anchoring structure formed on the first segment and at least one anchoring structure on the second segment; and a second support structure, wherein the second support structure is fixed to the anchoring structures, and wherein the second support structure connects the first segment to the second segment.

11 . The part of claim 1 , wherein the first segment forms a joint with the second segment.

12 . The part of claim 1 , wherein the first segment forms a joint with the second segment, and wherein the first segment and the second segment each include a hollow portion at the joint.

13 . The part of claim 1 , wherein the first segment forms a joint with the second segment, wherein the first segment and the second segment each include a hollow portion at the joint, and wherein the part further includes a fastener extending within the hollow portion of the first segment and within the hollow portion of the second segment.

14 . The part of claim 1 , further including a protrusion formed on the first segment and a recess formed on the second segment.

15 . A method of manufacturing a part, the method comprising:
removing material with a cutting machine to form a plurality of segments, the plurality of segments including a first segment, a second segment, a third segment, and a fourth segment, wherein the first segment includes an inner surface, an outer surface, a top surface, a bottom surface, a first side, and a second side; connecting the second segment to the first side of the first segment to form a first layer; connecting the third segment to the fourth segment to form a second layer; connecting the first layer to the second layer; and connecting a support structure that extends from the first layer to the second layer, the support structure connecting the first segment to the third segment via the inner surface of the first segment and an inner surface of the third segment.

16 . The method of claim 15 , further comprising:
forming anchoring structures, including at least one anchoring structure formed on the first layer and at least one anchoring structure on the second layer, the support structure fixed on the anchoring structures.

17 . The method of claim 15 , wherein the support structure connects a single layer of the part.

18 . The method of claim 16 , wherein the support structure connects the first layer to the second layer.

19 . The method of claim 16 , wherein a plurality of support structures are connected to a plurality of respective layers.

20 . The method of claim 16 , wherein a plurality of support structures are connected to a plurality of respective layers, and wherein the plurality of support structures includes at least two support structures positioned so as to connect different segments of the first layer.

Assignees

• Thermwood Corp

Inventors

• Susnjara Kenneth J

Classifications

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29L2031/757

  Moulds, cores, dies · CPC title

• B33Y40/20

  Post-treatment, e.g. curing, coating or polishing · CPC title

• B29C64/386

  Data acquisition or data processing for additive manufacturing · CPC title

• B29C64/188

  involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control (surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00) · CPC title