Abstract: Methods for forming an electrode for use in forming a honeycomb extrusion die. The method includes forming, by means of an additive manufacturing process, an electrode includes a base having a web extending from the base. The web defines a matrix of cellular openings. The method further includes forming a secondary electrode having a plurality of pins. The plurality of pins are shaped and arranged so as to mate with the matrix of cellular openings defined by the web of the electrode. The method further includes machining the electrode using the secondary electrode to smooth surfaces of the electrode formed by the additive manufacturing process.

Abstract: An apparatus and method for manufacturing a workpiece using optical dimensioning. The apparatus comprises a tool configured to alter at least one feature of the workpiece. An imaging system is coupled to the tool and defines an optical axis. The imaging system is configured to capture a plurality of images of the at least one feature of the workpiece. A controller comprises one or more processors. The controller is configured to analyze the plurality of images to determine measured dimensions of the at least one feature of the workpiece. The controller is further configured to define a three-dimensional path for operating the tool by applying a predefined modification to the measured dimensions of the at least one feature of the workpiece.

Abstract: Methods for forming an electrode for use in forming a honeycomb extrusion die. The method includes forming, by means of an additive manufacturing process, an electrode includes a base having a web extending from the base. The web defines a matrix of cellular openings. The method further includes forming a secondary electrode having a plurality of pins. The plurality of pins are shaped and arranged so as to mate with the matrix of cellular openings defined by the web of the electrode. The method further includes machining the electrode using the secondary electrode to smooth surfaces of the electrode formed by the additive manufacturing process.

Abstract: Methods of manufacturing an extrusion die (100) having a plurality of pins (600a-c) and a plurality of slots (601) defined by the plurality of pins, each pin having a base, the method including applying a coating material (604) over side walls of the bases of the pins of the extrusion die and removing a portion of the coating material coated over the side walls of the bases of the plurality of pins with a cutting tool (650). In some embodiments, the cutting tool has a cutting width (652) equal to a target slot width (640) of the slots. In some embodiments, applying the coating material over the side walls of the bases of the pins includes overcoating a coating material to a thickness that is greater than a thickness needed to define a target slot width of the slots.

Abstract: A method of manufacturing an extrusion die (102, 152, 302). The method comprises providing the extrusion die (102, 152, 302), the extrusion die (102, 152, 302) having a plurality of die pins (154, 316) defining a plurality of slots (156, 320), the plurality of die pins (154, 316) having an initial die pin width and an initial die pin depth and the plurality of slots having an initial slot width (Ws) and an initial slot depth (Ds), providing a micro-milling machine (104) with a spindle (122), providing a micro-cutting tool (120) coupled to the spindle (122), mounting the extrusion die (102, 152, 302) proximate the micro-cutting tool (120), and removing material from one or more die pins (154, 316) using the micro-cutting tool (120), the micro-cutting tool (120) making one or more cutting passes against the one or more die pins (154, 316) to remove the material. Micro-milling apparatuses and further methods are provided, as are other aspects.