Machined part and method of manufacture
View Patent ↗A machined part is provided. The machined part is formed from a porous substrate material that is machined to shape. After machining to shape, a resin is infused into the machined part precursor to a layer thickness depending on the end use of the finished part. The resin is then allowed to harden to complete the part. The finished part may be used as a prototype tool, a tool for forming other tools such as mold parts and finished tooling.
1. A method of forming a part using CNC machining, said method including:
securing a blank of material in place for machining on a machining apparatus, said material being porous;
providing machining instructions to the machining apparatus;
machining a part precursor from the blank of material in accordance with the machining instructions to form a machined surface;
infusing at least a portion of an exterior portion of the machined part precursor with a hardenable liquid; and
hardening the infused liquid to form a rigidified infused zone inwardly from the machined surface to produce a finished part consisting of one of a mold component and a pattern for boat manufacture with an exposed tool working surface.
2. The method of claim 1 wherein the blank of material includes cellulosic material.
3. The method of claim 2 wherein the cellulosic material includes fiberboard.
4. The method of claim 3 wherein at least a portion of the infused zone is at least about ⅛inch thick.
5. The method of claim 1 wherein the infusing includes flow by capillary action.
6. The method of claim 1 wherein the infusing includes the application of vacuum or pressure to the final part precursor.
7. The method of claim 1 wherein the blank of material has at least about 40% interstitial space therein capable of receiving and retaining the liquid.
8. The method of claim 1 wherein the liquid is hardened by curing.
9. The method of claim 1 wherein the liquid includes epoxy.
10. The method of claim 1 wherein the liquid includes thermosetting resin.
11. The method of claim 1 wherein the infused zone is at least about 0.125 inches thick.
12. The method of claim 11 wherein the infused zone has a thickness in a range of between about 0.125 and about 0.75 inches.
13. The method of claim 1 including using the finished part as a pattern for manufacturing a boat component.
14. The method of claim 13 including-using the finished part as a mold component.
15. The method of claim 14 including using the mold component to form at least a portion of a boat.
16. The method of claim 15 including forming a molded boat component using the finished part as a mold component.