Sacrificial structure preforms for thin part machining

Thin parts are often difficult to create by machining because they have insufficient static and dynamic stiffness. Accurate thin parts are difficult to achieve due to clamping forces, cutting forces, residual stresses, and chatter. Sacrificial structure preforms support the part during machining, but they are not part of the finished component. Preforms may be created in many ways, including forging, welding, gluing, casting, or additive processes. They can be used in many workpiece materials including metals, polymers, and ceramics. We describe a novel process that uses sacrificial structures to make machining insensitive to the thinness of finished parts.