WO2021061624A1

WO2021061624A1 - Automated tool maker

Info

Publication number: WO2021061624A1
Application number: PCT/US2020/051963
Authority: WO
Inventors: Charles Moncavage
Original assignee: Inspire Solutions Llc
Priority date: 2019-09-23
Filing date: 2020-09-22
Publication date: 2021-04-01

Abstract

A tool support manufacturing assembly includes a base, a gantry mounted on the base such that the gantry configured to move along a first axis, and a trolley mounted on the gantry, the trolley configured to move along a second axis, orthogonal to the first axis. A hole forming device is mounted on the trolley. The hole forming device is configured to move along a third axis, orthogonal to each of the first axis and the second axis. A frame is mounted on the base and extends above the trolley. A board support is attached to the frame above the trolley. The board support is configured to support a printed circuit board.

Description

TITLE OF THE INVENTION Automated Tool Maker

BACKGROUND OF THE INVENTION [0001] Field of the Invention

[0002] The present invention relates to an automated device for manufacturing a three-dimensional template to support a printed circuit board while the board is being populated with electronic components.

[0003] Prior Art

[0004] Printed circuit boards include electronic components, such as processor, resistors, and capacitors, that are attached to both a top and bottom surface of the board. Components are first attached to the top surface, and then the board is flipped over so that components can be attached to the bottom surface. Because the top surface components are now on the bottom, it can be a challenge to support the board so that the bottom surface components can be applied to the board. Some support fixtures have been developed that engage the top components to support the board, but such fixtures require air pressure to operate, are relatively expensive, and can be prone to malfunctions.

[0005] It would be beneficial to provide a board support fixture that does not require air pressure to operate, is inexpensive, and is not prone to malfunctions.

BRIEF SUMMARY OF THE INVENTION

[0006] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0007] In one embodiment, the present invention is a tool support manufacturing assembly comprising a base, a gantry mounted on the base such that the gantry configured to move along a first axis, and a trolley mounted on the gantry, the trolley configured to move along a second axis, orthogonal to the first axis. A hole forming device is mounted on the trolley. The hole forming device is configured to move along a third axis, orthogonal to each of the first axis and the second axis. A frame is mounted on the base and extends above the trolley. A board support is attached to the frame above the trolley. The board support is configured to support a printed circuit board.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate the presently preferred embodiments of the invention, and, together with the general description given above and the detailed description given below, serve to explain the features of the invention. In the drawings:

[0009] FIG. 1 is a perspective view of an automated tool maker assembly according to an exemplary embodiment of the present invention;

[0010] FIG. 2 is a side elevational view of a milling device with laser sensor reading the components of a printed circuit board and resultingly cutting into a template blank;

[0011] FIG. 3 is a schematic view showing movement of the milling device of FIG. 2 with components of varying sizes;

[0012] FIG. 4 is a perspective view of a housing in which the assembly of FIG. 1 can be inserted;

[0013] FIG. 5 is a side elevational view of the template blank of FIG. 2;

[0014] FIG. 6 is a schematic drawing of an exemplary control system for use with the assembly of FIG. 1;

[0015] FIG. 7 shows an exemplary pattern of movement of the milling device over a template blank; and

[0016] FIG. 8 is a schematic drawing of an alternative exemplary control system for use with the assembly of FIG. 1.

DETAILED DESCRIPTION

[0017] In the drawings, like numerals indicate like elements throughout. Certain terminology is used herein for convenience only and is not to be taken as a limitation on the present invention. The terminology includes the words specifically mentioned, derivatives thereof and words of similar import. The embodiments illustrated below are not intended to be exhaustive or to limit the invention to the precise form disclosed. These embodiments are chosen and described to best explain the principle of the invention and its application and practical use and to enable others skilled in the art to best utilize the invention.

[0018] Reference herein to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments necessarily mutually exclusive of other embodiments. The same applies to the term "implementation."

[0019] As used in this application, the word "exemplary" is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other aspects or designs. Rather, use of the word exemplary is intended to present concepts in a concrete fashion.

[0020] The word "about" is used herein to include a value of +/- 10 percent of the numerical value modified by the word "about" and the word "generally" is used herein to mean "without regard to particulars or exceptions."

[0021] Additionally, the term "or" is intended to mean an inclusive "or" rather than an exclusive "or". That is, unless specified otherwise, or clear from context, "X employs A or B" is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then "X employs A or B" is satisfied under any of the foregoing instances. In addition, the articles "a" and "an" as used in this application and the appended claims should generally be construed to mean "one or more" unless specified otherwise or clear from context to be directed to a singular form.

[0022] Unless explicitly stated otherwise, each numerical value and range should be interpreted as being approximate as if the word "about" or "approximately" preceded the value of the value or range. [0023] The use of figure numbers and/or figure reference labels in the claims is intended to identify one or more possible embodiments of the claimed subject matter in order to facilitate the interpretation of the claims. Such use is not to be construed as necessarily limiting the scope of those claims to the embodiments shown in the corresponding figures.

[0024] It should be understood that the steps of the exemplary methods set forth herein are not necessarily required to be performed in the order described, and the order of the steps of such methods should be understood to be merely exemplary. Likewise, additional steps may be included in such methods, and certain steps may be omitted or combined, in methods consistent with various embodiments of the present invention.

[0025] Although the elements in the following method claims, if any, are recited in a particular sequence with corresponding labeling, unless the claim recitations otherwise imply a particular sequence for implementing some or all of those elements, those elements are not necessarily intended to be limited to being implemented in that particular sequence.

[0026] The present invention provides an automated tool for manufacturing a template that can be used to support a printed circuit board (PCB) while the PCB is being populated with electronic components. The tool forms a template and underneath support for a PCB based on a "master" PCB. The template is then removed from the tool and placed on a PCB manufacturing machine to support individual PCBs that are advanced sequentially on the manufacturing machine for operations, such as applying solder paste, placing electronic components, heating/drying the solder paste to secure the components to the PCB, and any other operations.

[0027] Referring to FIG. 1, a tool assembly 100 ("assembly 100") uses a gantry mounted end effector, such as a drill 102, to move along a template blank 60 and drill, carve, or otherwise remove material from template blank 60 corresponding to electronic components 52 that are mounted on a first side 54 of a PCB 50. While drill 102 is shown, those skilled in the art will recognize that other end effectors in lieu of a drill can be used to remove material from template blank 60. By way of example only, drill 102 can be substituted for a laser. [0028] After template blank 60 is formed according to the requirements of a particular PCB 50, template blank 60 is removed from assembly 100 and placed on a PCB manufacturing machine (not shown) to support the top side 56 of a PCB 50 while components are attached to the bottom side of PCB 50.

[0029] When processing a top side 56 of PCB 50, template blank 60 is inserted on the manufacturing machine underneath PCB 50 and template blank 60 supports PCB 50 so that PCB 50 remains in a fixed and rigid position while processes are being performed on the top side 56 of PCB 50.

[0030] Assembly 100 includes a base 110 with a frame 112 that supports a gantry-style milling device 114 for drill 102. Frame 112 includes a pair of parallel spaced apart "X" rails 116, 118. Spaced apart vertical supports 122, 124 are each mounted on each rail 116, 118.

[0031] A grid pattern of holes 120 is provided in frame between rails 116, 118. Holes 120 are provided to allow clamps (not shown) to be inserted into holes 120 to secure template blank 60 to frame 112.

[0032] A spindle beam 132 extends the width of base 110 between vertical supports 122, 124. Spindle beam 132 supports a trolley 134 that is slidably mounted on spindle beam 132. Trolley 134 supports milling device 114. An "X" motor (shown in FIG. 6) receives electronic signals from controller 130 to rotate in a first direction to move trolley 134 in a first direction along an X axis and to rotate in a second direction to move trolley 134 in a second direction, opposite from the first direction. X motor allows trolley 134 to travel the length of spindle beam 132. [0033] While milling device 114 is supported by trolley 134, those skilled in the art will recognize that milling device 114 can be used on other manufacturing devices without mounting on trolley 134. Instead, milling device 114 can be mounted directly on a PCB screen printer (not shown) to process blanks 60 on the PCB manufacturing machine itself.

[0034] In such a situation, a blank 60 can be placed on the work table of the screen printer in the same place that a prefabricated tool would normally be placed when setting up for a production run. A circuit board 50 having a population of components 52 is positioned into the screen printer as per normal screen printing operation, as will be recognized by one having ordinary skill in the art. This process replicates the relative configuration of the blank 60 and the PCB 50 as shown in FIG. 1. Once the process is initiated, the X-Y gantry of the screen printing machine carries the end effector, such as drill 114, in a zig zag pattern between the blank 60 and the PCB 50 while simultaneously removing material from the blank 60 until a 3- Dimensional "nest" is formed into the blank 60. Since the newly created "nest" is now already positioned in the screenprinter relative to the model PCB, each consecutive PCB to be worked upon in this screen printer will be able to make use of the "nest" that was created for the model PCB and is ready for production run. [0035] Further, there are other parts of the PCB assembly process that may benefit more from having this ability onboard, such as, for example, routering/depaneling. In a depaneling operation, a PCB may have been assembled/populated in a multi-up configuration (a number of boards connected together throughout the assembly process) and subsequently parted by a routering machine into individual boards. In this case, the routering machine would produce a multi-up fixture for use in parting or separating subsequent boards as opposed to the screenprinting application where the present fixture is produced rom blank 60 for stabilizing the PCB 50 for printing.

[0036] A "Y" motor receives electronic signals from a controller 130 (shown in FIG. 6) to rotate in a first direction to move vertical supports 122, 124 in a first direction, perpendicular to the X axis and to rotate in a second direction to move vertical supports 122, 124 in a second direction, opposite from the first direction. Y motor allows vertical supports 122, 124 to travel the length of rails 116, 118. [0037] Milling device 114 is mounted on trolley 134 such that milling device 114 can translate vertically up and down in the "Z" direction. A "Z" motor (shown in FIG. 6) receives electronic signals from controller 130 to rotate in a first direction to move milling device 114 in a first direction, perpendicular to a plane defined by the X and Y axes, and to rotate in a second direction to move milling device 114 in a second direction, opposite from the first direction. Additionally, controller 130 sends electronic signals to milling device 114 to operate milling device 114 to rotate drill 102.

[0038] A laser 136 is mounted on top of milling device 114 co-axial with drill 102 and points generally vertically upwardly in the "Z" direction. In an exemplary embodiment, laser 136 generates a laser beam 137 that extends approximately 1° to 2° off the vertical. Laser beam 137 reflects off of a target and bounces back to a laser sensor 138, located adjacent to laser 136. The farther that the target is from laser sensor 138, the farther that the reflected light hits laser sensor 138 from laser 136, thereby allowing the distance from laser 136 to the target to be measured using triangulation. Those skilled in the art, however, will recognize that other types of laser measuring devices can be used.

[0039] Laser sensor 138 is electronically connected to controller 130 such that controller 130 transmits an electronic signal to a Z motor (shown schematically in FIG. 6) to move milling device 114 and drill 102 into or out of template blank 60 in a plane perpendicular to a plane defined by the X and Y axes, as will be discussed in more detail later herein.

[0040] Although not shown, the X, Y, and Z motors can translate their respective parts via cables/belts, lead screws, linear servos, or other known methods for linearly translating an object.

[0041] Frame 112 also includes a plurality of vertical supports 140 that are located at each corner of frame 112. An open rectangular frame 142 is mounted on top of the plurality of vertical supports 140 such that a generally parallelepiped open space is formed inside frame 112, vertical supports 140, and open rectangular frame 142.

[0042] Open rectangular frame 142 includes a front beam 144 connected to opposing parallel side beams 146, 148, which, in turn, are connected to a rear beam 150. A sliding beam 152 extends parallel to and between front beam 144 and rear beam 150. Sliding beam 152 has a first end 154 that rests on side beam 146 and an opposing second end 156 that rests on side beam 148. A ledge 158 extends outwardly from the bottom of sliding beam 152 toward front beam 144. Front beam 142 also includes a ledge (not shown) that extends outwardly from the bottom of front beam 142 toward sliding beam 152.

[0043] Sliding beam 152 is slidable along side beams 146, 148 to allow for infinite adjustment between sliding beam 152 and front beam 144 so that a PCB 50 can be laid on ledge 158 and the ledge on front beam 142 such that the ledges vertically support PCB 50. [0044] Optionally, as shown in FIG. 4, assembly 100 can be located within a housing 106 to keep outside debris from contaminating assembly 100 and also to prevent cuttings from drill 102 from contaminating the area outside of housing 106. Optionally, a vacuum (not shown) can be attached to housing 106 to suck debris away from the inside of housing 106. Assembly 100 can be mounted on a carriage (not shown) within housing 106 so that, when a door of housing is opened or removed, assembly 100 can at least partially slide out of housing to insert or remove PCB 50 and/or template blank 60.

[0045] Referring to FIGS. 2 and 5, template blank 60 can be constructed from a rigid core 62 having a first foam face 64 attached to one side of core 62 and a second foam face 66 attached to an opposing side of core 62. First face 64 has an exposed surface 68 and second face 66 has an exposed face 70. Faces 64, 66 can be constructed from open or closed cell foam. In an exemplary embodiment, the foam can be a high temperature foam so that template blank 60 can accompany PCB 50 into an oven to cure solder paste, if desired. Foam is provided as the material for faces 64, 66 due to the at least slight compressibility of foam.

[0046] Core 62 can have a generally truss-shaped cross section, with an upper planar surface 74, a lower planar surface 76, and a plurality of obliquely extending ribs 78 extending between upper planar surface 74 and lower planar surface 76, forming spaces 80 between adjacent ribs 78. The truss configuration provides a relatively rigid core 60 to prevent or reduce the possibility of warping.

[0047] Each of upper planar surface 74 and lower planar surface 76 can include a plurality of through holes 82, 84, respectively, that are in fluid communication with spaces 80. Spaces 80 and through holes 82, 84 allow for the connection of a vacuum (not shown) that can be used to draw PCB 50 against template blank 60 when components 52 are being added to PCB 50. It is desired that a perfect vacuum is not applied, but one with at least a slight amount of air leakage. Such air leakage tends to result in a better vacuum hold of PCB 50 onto template blank 60.

[0048] In an exemplary embodiment, template blank 60 has a cross sectional thickness of about 40 mm, with core 60 being about 6 mm thick and each of first foam face 64 and second foam face 66 being about 17 mm thick. Additionally, foam faces 64, 66 can be impregnated with carbon particles to produce an electrically conductive substrate and reduce static electricity build-up.

[0049] Controller 130 is configured to traverse milling device 114 in a fixed pattern across frame 112. In an exemplary embodiment, controller 130 can instruct the X motor to move milling device 114 toward rail 116 and instruct the Y motor to move toward the front of frame 112, close to front beam 144 as a starting position. Then, controller 130 can instruct the X motor to traverse across spindle beam 132 until milling device 114 is at rail 118. Controller 130 can then instruct the Y motor to move vertical supports 122, 124 a predetermined distance toward rear beam 150 and then instruct the X motor to traverse across spindle beam 132 until milling device 114 is at rail 116. In an exemplary embodiment, the predetermined distance can be less than the width of drill 102 so that no area under drill 102 is missed as drill 102 traverses in the X and Y directions. The process can be repeated by sequentially instructing the Y motor to index a predetermined distance toward rear beam 150 and then instruct the X motor to traverse between rails 116, 118. An exemplary pattern of movement is shown in FIG. 7.

[0050] In an exemplary embodiment, laser 136 and laser sensor 138 cooperate with controller 130 in the following manner. Laser sensor 138 has a first output channel 160 that feeds an "up" signal to the Z motor and a second output channel

162 that feeds a "down" signal to the Z motor. Laser sensor 136 is set to a predetermined datum distance. In an exemplary embodiment, the predetermined datum distance point can be about 45 mm from laser sensor 138. Referring to FIG.

3, in an exemplary embodiment, the predetermined datum distance is a sensing range formed by a band 164 of about 45 mm +/- about 0.5 mm from laser sensor

138. Components 52A, 52B, 52C having different vertical dimensions are shown.

When laser 137 encounters component 52A, and reflects off component 52A to laser sensor 138, laser sensor 138 transmits an electronic signal that operates Z motor to move milling device 114 downward. When laser 137 encounters component 52B, laser sensor 138 does not transmit any electronic signal to operate

Z motor. When laser 137 encounters component 52C, laser sensor 138 transmits a first electronic signal to controller 130, which in turn transmits a second electronic signal to operate Z motor to move milling device 114 upward.

[0051] First output channel 160 triggers output to Z motor via controller 130 to move downward based on the detection of a surface in the foreground of the sensing range and second output channel 162 triggers output to Z motor to move upward based on the detection of a surface in the background of the sensing range. The detection of a surface within the sensing range is a neutral position and no vertical motion or activation by the Z motor is called for.

[0052] To use assembly 100, a PCB 50 is selected. PCB 50 can start with no components 52 attached to either side 54, 56 of PCB 50. Sliding beam 152 is adjusted so that PCB 50 can rest on ledge 158 and the ledge on front beam 142. A template blank 60 is placed on frame 112 so that face 68 of first face 64 is facing drill 102. Template blank 60 can be secured in place so that template blank 60 does not move.

[0053] Controller 130 can be activated so that drill 102 is moved via the X and Y motors to a starting point, such as at the front of frame 112 at rail 116. Controller 130 then instructs X and Y motors to operate as described above. At this point,

PCB 50 is not over laser sensor 136 and second output channel 162 triggers the Z motor to move milling device 114 upwardly. When laser sensor 136 encounters edge of PCB 50, first output channel 160 of laser sensor 136 triggers Z motor to move milling device 114 downward. Drill 102 is inserted into template blank 60 and starts to drill/carve into template blank 60.

[0054] The X motor traverses milling device 114 along spindle beam 152. The entire time that milling device 114 is being traversed, first output channel 160 is transmitting a signal to controller 130 that laser sensor 136 is spaced the predetermined datum distance from PCB 50 and Z motor is not instructed to move up or down. When X motor traverses laser sensor 136 beyond the edge of PCB 50, laser sensor 136 senses a background object (e.g. the lid of housing 106), so second output channel 162 transmits a signal to controller 130 and controller 130 in turn transmits a signal to Z motor to move milling device 114 upward and out of template blank 60.

[0055] The process is repeated until a generally rectangular groove 72 is formed in first foam face 64 of template blank 60. Groove 72 is generally the same size as PCB 50, with an additional perimeter of about one half the diameter of drill 102 extending around each side. The value of one half the diameter of drill 102 corresponds to the fact that laser beam 137 is coaxial with drill 102 and Y motor stops when laser beam 137 passes off of PCB 50.

[0056] Alternatively, the dimensions of PCB 50 can be input into a touch screen 131 electronically connected to controller 130 so that, when laser sensor 136 locates PCB 50, controller 130 can determine how far to travel in each of the X direction and the Y direction to eliminate lost time when laser sensor 136 is beyond PCB 50 and cannot receive any signals from first channel 160.

[0057] Groove 72 can be used to support PCB 50 when PCB 50 is first having solder paste and components 52 applied to the first side 54 of PCB 50. This is beneficial to prevent PCB 50 from flexing or bowing, particularly during the solder applying step, so that the squeegee (not shown) that applies solder to PCB 50 maintains full contact with PCB 50 as the squeegee traverse across PCB 50.

[0058] After groove 72 is cut, template blank 60 can be flipped so that exposed face 70 of second foam face 66 is facing drill 102. PCB 50 with components 52 attached to first side 54 of PCB 50 is placed with components 52 facing downward on ledge 158 and the ledge on front beam 142 such that the ledges vertically support PCB 50.

[0059] Laser 136 and laser sensor 138 are operated as described above and controller 130 controls X and Y motors as described above to traverse across first side 54 of PCB 50 with components 52. As laser sensor 138 senses components, first output channel 160 transmits a signal to controller 130, which in turn transmits a signal to Z motor to move downward, away from component 52, until the predetermined datum distance is sensed by laser sensor 138. At this point, Z motor stops until first or second output channels 160, 162 sense a change in distance from component 52. The process is repeated until the entirety of PCB 50 is traced and grooves 78 corresponding to the dimensions of components 52 on PCB 50 are carved in second face 66 of template blank 60.

[0060] In an exemplary embodiment, the depth of grooves 73 are equal to the heights of corresponding components 52 on PCB 50 so that, when template blank

60 is inserted into a PCB manufacturing machine during PCB manufacturing, components 52 on first side 54 are supported by foam material of template blank 60. This feature is beneficial, particularly for densely populated PCBs that do not have a lot of potential support in areas with no components on a particular PCB. [0061] As discussed above, a perimeter equivalent to one half the diameter of drill 102 is formed around each groove 73 as grooves 73 are cut. This result can be beneficial to accommodate components 52 that are not placed in exactly the same location on successive PCBs during the PCB manufacturing process. By way of example only, some components 52 on one PCB 50 may be rotated 2-3 degrees relative to a master PCB, while other components 52 may be tilted 2-3 degrees relative to the vertical. Further, components 52 that are intended to be placed at the same location on a plurality of PCBs 50 might be from different batches, resulting in components having slightly differing dimensions. The extended perimeter, along with foam face 66 being constructed form a resilient foam material, may be able to accommodate for some of these discrepancies.

[0062] After template blank 60 is cut on both faces 64, 66, template blank 60 can be removed from assembly 100 and used with a PCB manufacturing machine. [0063] An alternative laser sensor 238 is shown schematically in FIG. 8. Laser sensor 238 generates a single analog output 260 to controller 130. The output can be calibrated on a scale of 0-10 V, with a change in voltage resulting in a predetermined movement along the Z axis. By way of example only, a voltage of 4.8-5.2 volts can indicate that milling device 114 is in a good place with respect to the Z axis and does not need to move; a voltage of less than 4.8 volts can indicate that milling machine 114 is too close to electronic components 52 and has to move down, thereby plunging drill 102 into blank 60 to carve out a groove 73; and a voltage of greater than 5.2 volts can indicate that milling machine 114 is too far from electronic components 52 or board 50 and has to move up, thereby removing drill 102 from blank 60.

[0064] The range of 4.8 - 5.2 volts is an arbitrary range and can be adjusted to provide a larger or smaller range if different levels of sensitivity are required.

Additionally, controller 130 can be programmed to stop all Z axis movement if a voltage lower than a first pre-set value or a voltage higher than a second pre-set value is recorded by controller 130, indicating a possible error somewhere in assembly 100.

[0065] It will be further understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated in order to explain the nature of this invention may be made by those skilled in the art without departing from the scope of the invention as expressed in the following claims.

Claims

CLAIMS I claim :

1. A tool support manufacturing assembly comprising: a base; a gantry mounted on the base, the gantry configured to move along a first axis; a trolley mounted on the gantry, the trolley configured to move along a second axis, orthogonal to the first axis; a hole forming device mounted on the trolley, the hole forming device configured to move along a third axis, orthogonal to each of the first axis and the second axis; a frame mounted on the base, the frame extending above the trolley; and a board support attached to the frame above the trolley, the board support configured to support a printed circuit board.

2. The tool support manufacturing assembly according to claim 1, further comprising a distance measuring device mounted on the hole forming device.

3. The tool support manufacturing assembly according to claim 2, wherein the distance measuring device comprises a laser.

4. The tool support manufacturing assembly according to claim 3, further comprising a laser sensor mounted on the hole forming device.

5. The tool support manufacturing assembly according to claim 4, further comprising a controller electronically connected to the gantry, the trolley, and the hole forming device to move the gantry, the trolley, and the hole forming device along their respective axes, and electronically connected to the laser sensor.

6. The tool support manufacturing assembly according to claim 5, wherein the laser sensor in configured to transmit a first electronic signal to the controller, and wherein the controller is configured to transmit a second electronic signal to the hole forming device based on the first signal.

7. The tool support manufacturing assembly according to claim 6, wherein the laser sensor has a first output channel configured to trigger a first output to the hole forming device via the controller to move in a first direction and a second output channel configured to trigger a second output to the hole forming device via the controller to move in a second direction, opposite the first direction.

8. The tool support manufacturing assembly according to claim 7, wherein the laser sensor is configured such that detection of a surface within a predetermined sensing range is a neutral position and the controller does not transmit a signal to move the hole forming device.

9. The tool support manufacturing assembly according to claim 1, wherein the hole cutting device comprises a laser.

10.The tool support manufacturing assembly according to claim 1, wherein the frame comprises a plurality of vertical supports, with side beams attached to adjacent vertical supports.

11.The tool support manufacturing assembly according to claim 10, further comprising a beam slidingly mounted on the side beams.

12. The tool support manufacturing assembly according to claim 11, wherein, when the beam is mounted on the side beams, the beam has a longitudinal axis extending along a beam axis, parallel to the second axis.

13.The tool support manufacturing assembly according to claim 1, further comprising a blank configured to be removably attached to the base, the blank having: a rigid core; a first foam face attached to one side of the core; and a second foam face attached to an opposing side of the core.

14.The tool support assembly according to claim 13, wherein the core comprises a generally truss-shaped cross section having a plurality of ribs and spaces between adjacent ribs.

15.The tool support assembly according to claim 13, wherein each of first foam face and the second foam face includes a plurality of through holes in fluid communication with the spaces.