Additively manufactured geometry optimized drilling jigs and methods of making and using the same
Drilling jigs are provided which include a one-piece jig body (preferably additively manufactured from laser-sintered metallic (e.g., aluminum alloy) powders) having at least one set of cylindrical sockets that are spatially separated from one another, and a web member joining the at least one set of sockets. Cylindrical bushings may thus be positioned within each of the cylindrical sockets so as to define respective cylindrical guideways for a drill bit. According to certain embodiments, the web member may be planar and oriented parallel to a substantially longitudinal bisecting plane of the cylindrical sockets.
1 . A drilling jig comprising:
(i) a one-piece jig body which includes:
a plurality of cylindrical sockets that are spatially separated from one another; and
a web member joining the plurality of cylindrical sockets to one another to form a conjoined set of cylindrical sockets having an opposed set of endmost cylindrical sockets;
(ii) a plurality of cylindrical bushings, wherein each of the cylindrical bushings is received within a respective one of the cylindrical sockets and defines a cylindrical guideway for a drill bit; and
(iii) pairs of axially elongated end stand-off members attached to respective exterior cylindrical surfaces of each of the endmost cylindrical sockets so that the end stand-off members are circumferentially separated from one another about the exterior cylindrical surfaces of the endmost cylindrical sockets, wherein each of the elongated end stand-off members is of sufficient axial length so as to establish a clearance gap between a bottom edge of the jig body and a surface of a part to be drilled.
2 . The drilling jig according to claim 1 , wherein
the plurality of cylindrical sockets includes an adjacent pair of inner cylindrical sockets between the endmost cylindrical sockets, and wherein
the web member includes an intermediate web member joining the adjacent pair of inner cylindrical sockets to one another, and wherein
the intermediate web member includes an axially elongated intermediate stand-off member extending from a bottom edge of the intermediate web member and being of sufficient axial length so as to establish a clearance gap between a bottom edge of the intermediate web member and the surface of the part to be drilled.
3 . The drilling jig according to claim 2 , wherein the stand-off members are either solid or hollow.
4 . The drilling jig according to claim 1 , wherein the jig body is a one-piece additively manufactured structural unit.
5 . The drilling jig according to claim 4 , wherein the jig body is formed of an additively laser sintered metallic powder.
6 . The drilling jig according to claim 5 , wherein the metallic powder comprises an aluminum alloy powder.
7 . The drilling jig according to claim 1 , wherein the web member is planar, and wherein the planar web member is oriented parallel to a substantially longitudinal bisecting plane of each of the cylindrical sockets.
8 . The drilling jig according to claim 7 , wherein the jig body is a one-piece additively manufactured structural unit.
9 . The drilling jig according to claim 8 , wherein the jig body is formed of an additively laser sintered metallic powder.
10 . The drilling jig according to claim 9 , wherein the metallic powder comprises an aluminum alloy powder.
11 . The drilling jig according to claim 1 , wherein each of the cylindrical bushings includes a flange.
12 . The drilling jig according to claim 1 , wherein each of the cylindrical bushings is adhesively joined to the respective one of the cylindrical sockets.
13 . A method of fabricating the drilling jig according to claim 1 , comprising the steps of:
(a) additively sintering layers of a metallic powder to form the one-piece jig body which includes the plurality of cylindrical sockets that are spatially separated from one another, and the web member joining the plurality of cylindrical sockets; and thereafter
(b) inserting the cylindrical bushings defining respective cylindrical guideways into respective ones of the cylindrical sockets.
14 . The method according to claim 13 , wherein the metallic powder comprises an aluminum alloy.
15 . The method according to claim 13 , wherein step (b) comprises adhesively joining the cylindrical bushings to the respective ones of the cylindrical sockets.
16 . The method according to claim 13 , wherein step (a) is conducted by 3D laser-sintering of the metallic powder.
17 . A method of drilling apertures in a workpiece comprising:
(a) positioning the drilling jig according to claim 1 relative to a surface of the workpiece so as to align the cylindrical guideways of the bushings with respective locations on the surface of the workpiece where apertures are to be drilled, and thereafter
(b) operating a drill bit within the cylindrical guideways to drill the apertures through the workpiece.
18 . The method according to claim 17 , wherein
step (b) comprises allowing shavings of removed material from the workpiece to be removed from the respective locations through the clearance gap established by the elongated end stand-off members.