3D printing hub cover and manufacturing method thereof

Abstract

The invention belongs to the technical field of automobile part manufacturing, and particularly relates to a 3D printing hub cover and a manufacturing method thereof. The hub cover is integrally formed through 3D printing and comprises an annular main frame with large rigidity and an auxiliary frame connected into the main frame and small in rigidity, the main frame is provided with an installation buckle, and the center of the auxiliary frame is provided with a display block. The auxiliary frame is of a three-dimensional network structure, the rigidity of the auxiliary frame can be adjusted and controlled by adjusting parameters such as the number, the rod diameter or the length of the connecting rods, and rigidity gradient design of the main frame and the auxiliary frame is achieved. The main frame comprises an outer supporting ring, an inner supporting ring and bridging blocks connecting the outer supporting ring and the inner supporting ring, and a gap between the bridging blocks forms a flow guide opening. And the mounting buckle is provided with reinforcing ribs and anti-skid grains. According to the manufacturing method, a selective laser sintering technology is adopted, and a PA series or PEEK material is used for printing forming. A complex integrated structure is achieved, and the structure stability, the buffering performance, the light weight and the high personalized design freedom degree are achieved.

Description

Technical Field

[0001] This invention belongs to the field of automotive parts manufacturing technology, specifically relating to a 3D printed wheel hub cap and its manufacturing method. Background Technology

[0002] Wheel covers, as an important component of vehicle wheels, are widely installed on the outside of the wheel rims of various automobiles. Their main functions are to decorate the wheel rims, enhance the overall aesthetics of the vehicle, and to some extent prevent dust and mud from entering and protect the wheel bolts. Currently, most wheel cover products on the market are mass-produced using traditional injection molding. This process is mature, efficient, and suitable for producing parts with relatively regular structures and uniform shapes. However, injection molding often presents manufacturing difficulties for products with extremely complex internal structures or highly integrated irregular configurations. Its high mold costs and inflexible design changes significantly restrict the development of wheel cover structural innovation and in-depth personalized design.

[0003] From a product structure and performance perspective, wheel covers typically exist as a single component, requiring a balance between installation stability, dynamic balance and stability under high-speed rotation, and resistance to road impacts during driving. Simultaneously, with the increasing trend towards personalized automotive consumption, the market is demanding more diverse styling options and more distinctive, three-dimensional brand logos for wheel covers. Therefore, effectively responding to these growing personalized needs while meeting basic functionality and reliability has become a challenge in wheel cover design and manufacturing. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a 3D-printed wheel hubcap and its manufacturing method. The purpose of this invention is to overcome the limitations of traditional wheel hubcaps in achieving both highly personalized appearances and complex functional structures.

[0005] The first aspect of the present invention provides a 3D printed hubcap, comprising a main frame that is generally ring-shaped and a sub-frame connected within the main frame; a mounting buckle for fastening and fixing the hubcap to a vehicle hub is provided on one side of the main frame; a display block for displaying logos is provided in the center of the sub-frame; wherein, the main frame has a first rigidity, the sub-frame is a three-dimensional network structure and has a second rigidity, and the first rigidity is greater than the second rigidity; the hubcap is integrally formed by 3D printing.

[0006] As a further optimization of the aforementioned 3D printed hubcap, the three-dimensional network structure of the subframe includes multiple connecting rods and connecting nodes; each connecting node extends outward with several connecting rods, and the two ends of each connecting rod are connected to different connecting nodes.

[0007] As a further optimization of the aforementioned 3D printed hubcap, the main frame includes an outer support ring integrally formed on the outer circumference, an inner support ring integrally formed on the inner circumference, and multiple bridging blocks arranged in a ring array along the circumference; the two ends of the bridging blocks are fixedly connected to the outer support ring and the inner support ring respectively; the gaps between adjacent bridging blocks form flow guides.

[0008] As a further optimization of the aforementioned 3D printed hubcap, the three-dimensional network structure of the subframe is centrally symmetrical and extends radially from the central region to the outer periphery; the center of gravity of the subframe coincides with the rotation axis of the vehicle hub.

[0009] As a further optimization of the aforementioned 3D printed hubcap, the rigidity of the subframe is controlled by adjusting the structural parameters of the three-dimensional network structure, so that the first rigidity is greater than the second rigidity. The structural parameters include at least one of the following: the average number of connecting rods directly connected to each connecting node, the average diameter of each connecting rod, and the average length of each connecting rod.

[0010] As a further optimization of the aforementioned 3D printed hubcap, the base of the mounting buckle is integrally formed with the main frame, and its main body protrudes outward along the radial direction of the hub; the outer surface of the protruding part of the mounting buckle is provided with anti-slip texture, and the inner surface is provided with reinforcing ribs.

[0011] As a further optimization of the aforementioned 3D printed hubcap, the display block has an iconic configuration and is integrally formed with the main three-dimensional network structure of the sub-frame through 3D printing.

[0012] As a further optimization of the aforementioned 3D printed hubcap, the display block includes a flat base plate and an integrated logo configuration on the base plate. The base plate is integrally formed in the center of the three-dimensional network structure of the sub-frame through 3D printing.

[0013] As a further optimization of the above-mentioned 3D printed hubcap, the cross-sectional area of ​​the outer support ring is defined as S1, the cross-sectional area of ​​the inner support ring is defined as S2, and the average cross-sectional area of ​​each connecting rod in the three-dimensional network structure of the subframe is defined as S3, satisfying the relationship: (S1+S2) / S3=4.0~22.5.

[0014] A second aspect of the present invention is to provide a method for manufacturing the above-mentioned 3D printed hubcap, comprising the following steps: S1. Establish a three-dimensional digital model of the hubcap; S2. Selective laser sintering technology is used to print the molding material in one piece based on a three-dimensional digital model to obtain the wheel hub cover blank; S3. Post-process the wheel hub cover blank to remove residual powder and obtain the 3D printed wheel hub cover. The molding material is selected from PA11, PA12, glass fiber reinforced PA12 or PEEK.

[0015] Beneficial effects Compared with existing technologies, the 3D-printed hubcap provided by this invention ensures a secure installation with the hub and high-speed rotational stability. Through differentiated stiffness design of the main frame and sub-frame, a stable installation base and a buffered display area are organically integrated, effectively resisting vibrations and impacts during driving and reducing the risk of structural damage. The sub-frame adopts a three-dimensional network structure with adjustable key structural parameters, providing high design flexibility and enabling precise control to achieve the required mechanical properties while maintaining lightweight construction. The air vents on the hubcap naturally form efficient ventilation and heat dissipation channels, helping to improve the heat dissipation efficiency of the internal components of the hub. The reinforced design of the mounting clips further enhances the reliability and durability of the fastening. Furthermore, the one-piece 3D printing manufacturing process not only perfectly replicates the complex integrated structure, achieving the stiffness gradient of the main and sub-frames and the internal three-dimensional network that are difficult to process using traditional methods, but also avoids the assembly process, improving production consistency and design freedom. Attached Figure Description

[0016] Figure 1 and Figure 2 This is a schematic diagram of the hub cover of the present invention.

[0017] Figure 3 and Figure 4 This is a schematic diagram of the structure of a three-dimensional network for the subframe.

[0018] Figure 5 and Figure 6 A schematic diagram showing the connection between the main frame and the mounting clips.

[0019] In the diagram, 1. Main frame; 2. Sub-frame; 11. Outer support ring; 12. Inner support ring; 13. Bridge block; 14. Flow guide; 16. Mounting buckle; 17. Reinforcing rib; 18. Anti-slip texture; 21. Connecting rod; 22. Connecting node; 29. ​​Display block. Detailed Implementation

[0020] The present invention is further illustrated below with specific embodiments. These embodiments are exemplary and intended to illustrate the problem and explain the present invention, and are not intended to be limiting.

[0021] Example 1 This embodiment describes the structure of the hubcap. For example... Figures 1 to 6 As shown, the wheel cover is circular in shape and is integrally formed by 3D printing. It includes a main frame 1, which is roughly circular in shape, and a sub-frame 2 connected within the main frame 1. One side of the main frame 1 has several mounting clips 16 for securing the wheel cover to the vehicle's wheel rim. The sub-frame 2 has a display block 29 in its center, which displays specific logos, such as the vehicle brand logo.

[0022] The main frame 1 has high rigidity. Its outer circumference is integrally formed with an outer support ring 11, and its inner circumference with an inner support ring 12. An annular gap is formed between the outer and inner support rings 11 and 12. Multiple bridging blocks 13 are arranged circumferentially within this annular gap. Each bridging block 13 is fixedly connected at both ends to the outer and inner support rings 11 and 12, respectively, thus connecting the outer and inner support rings 11 and 12 into a stable integral structure. The bridging blocks 13 are arranged in a circular array along the circumference of the main frame 1. The sub-frame 2 has lower rigidity than the main frame 1 and can possess a certain degree of elasticity or flexibility. The sub-frame 2 is an integrally formed three-dimensional network structure composed of numerous connecting rods 21 and connecting nodes 22. Each connecting node 22 extends several connecting rods 21 outwards, and the two ends of each connecting rod 21 are connected to different connecting nodes 22. By adjusting the structural parameters of the three-dimensional network structure of the sub-frame 2, the rigidity of the sub-frame 2 can be controlled so that the rigidity of the sub-frame 2 is less than that of the main frame 1. Preferably, the rigidity of the sub-frame 2 is adjusted to be much less than that of the main frame 1.

[0023] In the three-dimensional network structure of the sub-frame 2, there are several adjustable structural parameters, such as: the average number of connecting rods 21 directly connected to each connecting node 22, the average diameter of each connecting rod 21, and the average length of each connecting rod 21. By adjusting these structural parameters, the rigidity of the sub-frame 2 can be finely controlled, thereby precisely adjusting the sub-frame 2's ability to resist deformation under external forces.

[0024] Regarding the average number of connecting rods 21 directly connected to each connecting node 22, the regulation law on the flexibility of the three-dimensional network structure of the sub-frame 2 is as follows: When the number of connecting rods 21 is increased, the rigidity and support efficiency of the entire network structure will be enhanced simultaneously, while the flexibility will be weakened accordingly. This is because the more connection points between connecting nodes 22, the more significant the mutual restraint effect between the components of the structure, thus promoting the overall rigidity improvement; conversely, reducing the number of connecting rods 21 can effectively improve the flexibility of the three-dimensional network structure.

[0025] Regarding the average diameter of each connecting rod 21, its influence on the flexibility of the three-dimensional network structure of the sub-frame 2 follows this pattern: Increasing the diameter of the connecting rod 21 strengthens its own resistance to deformation, thereby improving the rigidity and support performance of the entire network structure, while simultaneously reducing structural flexibility. From a mechanical perspective, a larger rod diameter imparts higher inherent stiffness to the connecting rod 21, enabling it to withstand stronger deformation under external forces; conversely, reducing the diameter of the connecting rod 21 improves the flexibility of the three-dimensional network structure.

[0026] Regarding the average length of each connecting rod 21, its control over the flexibility of the three-dimensional network structure of the sub-frame 2 follows this pattern: Increasing the length of the connecting rod 21 directly leads to an increase in the spacing between adjacent connecting nodes 22. This change reduces the rigidity and support stability of the entire network structure while enhancing its flexibility. This is because the longer the connecting rod 21, the easier it is for it to undergo bending deformation, providing more sufficient deformation buffer space for the sub-frame 2; conversely, shortening the length of the connecting rod 21 will correspondingly reduce the flexibility of the three-dimensional network structure.

[0027] The three-dimensional network structure of the subframe 2 has a large degree of design freedom. In some preferred embodiments, the three-dimensional network structure of the subframe 2 is centrally symmetrical and extends radially from the central region to the periphery, ensuring that its center of gravity is precisely aligned with the rotation axis of the vehicle wheel hub, thereby ensuring the stability of the wheel hub cover during high-speed rotation with the wheel hub.

[0028] In the three-dimensional network structure of the sub-frame 2, the cross-sectional area (corresponding to the thickness of the ring) of the outer support ring 11 is denoted as S1, the cross-sectional area (corresponding to the thickness of the ring) of the inner support ring 12 is denoted as S2, and the average cross-sectional area of ​​each connecting rod 21 in the three-dimensional network structure of the sub-frame 2 is denoted as S3. In some preferred embodiments, (S1+S2) / S3 = 4.0~22.5 is satisfied. This can construct a reasonable stiffness difference between the main frame 1 and the sub-frame 2, while adapting to the characteristics of 3D printing technology and practical needs. From the perspective of structural support, the outer support ring 11 and the inner support ring 12 adopt a relatively thick structure, which can significantly strengthen the overall rigidity of the main frame 1, providing a stable and reliable foundation support for the mounting buckles 16 distributed on one side of the main frame 1, ensuring that the mounting buckles 16 are firmly fastened to the vehicle wheel hub, and even under the condition of vehicle bumpy driving or high-speed rotation of the wheel hub, the mounting buckles 16 can be prevented from loosening due to deformation of the main frame 1. From a buffering and protection perspective, the small average cross-sectional area of ​​the connecting rod 21 in the sub-frame 2 effectively reduces the rigidity of the sub-frame 2, giving it good deformability. This provides ample buffer space for the central display block 29 of the sub-frame 2 during high-speed rotation of the wheel hub and road bumps, reducing the impact of external forces on the connection points of the display block 29 and preventing overall structural damage due to stress concentration. Currently, the strength of 3D printed products is often inferior to traditional injection-molded parts (taking plastic parts as an example). However, the structural arrangement of the main frame 1 (high rigidity) and the sub-frame 2 (low rigidity) provides the sub-frame 2 with a certain degree of buffering, which can compensate for the relatively weak strength of 3D printed parts to some extent. Furthermore, the realization of these structural parameters relies on the high degree of freedom in forming complex three-dimensional network structures using 3D printing. This not only meets the practical functional requirements of the wheel hub cover but also fully leverages the advantages of 3D printing to meet more personalized wheel hub structure design requirements.

[0029] As described above, the display block 29 in the center of the sub-frame 2 is used to present a specific logo, and its specific forming and placement can take different forms. In some embodiments, the display block 29 can be directly designed as the configuration of the specific logo, and integrally formed with the main three-dimensional network structure of the sub-frame 2 through 3D printing, so that the logo and the three-dimensional network structure of the sub-frame 2 are integrated together to form a stable integrated structure. In other embodiments, the display block 29 can be designed as a combination of a flat substrate and a specific logo. The substrate is preferably circular and integrally formed in the center of the three-dimensional network structure through 3D printing. The specific logo is integrally formed on the substrate and simultaneously 3D printed.

[0030] As described above, the mounting buckle 16 is used to fasten and fix the hubcap to the wheel hub of the vehicle. As shown in the attached drawings, each mounting buckle 16 is located on one side of the main frame 1, extending approximately along the axial direction of the hubcap. The root of the mounting buckle 16 is integrally formed with the main frame 1 during 3D printing to ensure the stability of the connection, and the free end extends outward along the axial direction. In some preferred embodiments, the main body of each mounting buckle 16 protrudes outward along the radial direction of the wheel hub to adapt to the fastening position of the wheel hub and achieve a reliable snap-fit. The outer surface of the protruding part is also provided with anti-slip texture 18, and the inner surface of the protruding part is further provided with reinforcing ribs 17, which can further improve the stability and durability after fastening.

[0031] As described above, an annular gap is formed between the outer support ring 11 and the inner support ring 12 of the main frame 1, and the bridge connecting blocks 13 are evenly arranged in a ring array within this annular gap. In this way, the gaps between adjacent bridge connecting blocks 13 naturally form guide ports 14 with a large opening. These guide ports 14 have excellent ventilation and heat dissipation performance, providing a channel for air circulation inside and outside the wheel hub, thereby improving the heat dissipation efficiency of the mechanical components inside the wheel hub, especially optimizing the cooling effect of the brake disc, and ensuring its stable performance under high-intensity working conditions.

[0032] Example 2 This embodiment describes a method for manufacturing a hubcap.

[0033] A 3D model of the wheel hub cover was created using 3D design software, and then 3D printed using SLS technology. SLS stands for Selective Laser Sintering, which is one of the mainstream powder bed fusion (PBF) technologies in industrial additive manufacturing. SLS uses the powder bed as a natural support, and suspended structures, internal cavities, complex lattices, and deep cavity channels of parts can be directly printed without the need for designing supports or subsequent support removal processes.

[0034] The preferred molding materials for 3D printing are PA11 (polyundecanoamide), PA12 (polydodecanoamide), PA12GF (glass fiber reinforced polydodecanoamide), and PEEK (polyetheretherketone). PA11 and PA12 are conventional nylon-based engineering plastics, possessing excellent toughness and wear resistance, high molding precision, and relatively moderate processing costs. PA12GF is obtained by adding glass fiber to a PA12 matrix, significantly improving rigidity and deformation resistance compared to pure PA12, resulting in superior structural stability. PEEK is a high-performance specialty engineering plastic, exhibiting outstanding high-temperature resistance, chemical corrosion resistance, and weather resistance, making it suitable for demanding operating conditions. These materials balance structural strength and weather resistance, with a temperature range covering -40℃ to 80℃, making them suitable for the environmental requirements of automotive exterior parts.

[0035] The printing parameters are set as follows: laser power is controlled at 180~220W, scanning speed is 3000~4000mm / s, scanning spacing is set at 0.12~0.15mm, and single-layer powder thickness is about 0.1mm.

[0036] The printing chamber is protected by nitrogen, keeping the oxygen content between 0.1% and 5%. The molding temperature is set at 170-180℃, which is close to the melting point of PA12 and can effectively improve the interlayer bonding strength of the printed parts. The cooling rate is controlled at 5-8℃ / h, which reduces the internal stress of the printed parts by slow cooling and avoids defects such as cracking and deformation in the finished products.

[0037] After printing is complete, remove the printed part, clean the surface and interior of any residual powder, and you will get the finished wheel hub cover.

[0038] The above embodiments are exemplary and are intended to illustrate the technical concept and features of the present invention, so that those skilled in the art can understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made according to the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A 3D-printed wheel hub cover, characterized in that, The system includes a main frame (1) that is in the shape of a ring and a sub-frame (2) connected within the main frame (1); one side of the main frame (1) is provided with a mounting buckle (16) for fastening and fixing the hubcap to the vehicle hub; the center of the sub-frame (2) is provided with a display block (29) for displaying the logo; wherein, the main frame (1) has a first rigidity, the sub-frame (2) is a three-dimensional network structure and has a second rigidity, and the first rigidity is greater than the second rigidity; the hubcap is integrally formed by 3D printing.

2. The 3D printed hub cap according to claim 1, characterized in that, The three-dimensional network structure of the subframe (2) includes multiple connecting rods (21) and connecting nodes (22); each connecting node (22) extends outward with several connecting rods (21), and the two ends of each connecting rod (21) are connected to different connecting nodes (22).

3. The 3D printed hub cap according to claim 2, characterized in that, The main frame (1) includes an outer support ring (11) integrally formed on the outer circumference, an inner support ring (12) integrally formed on the inner circumference, and a plurality of bridging blocks (13) arranged in a ring array along the circumference; the two ends of the bridging blocks (13) are fixedly connected to the outer support ring (11) and the inner support ring (12) respectively; the gap between adjacent bridging blocks (13) forms a flow guide (14).

4. The 3D printed hub cap according to claim 2, characterized in that, The three-dimensional network structure of the subframe (2) is centrally symmetrical and extends radially from the central region to the outer periphery; the center of gravity of the subframe (2) coincides with the rotation axis of the vehicle wheel hub.

5. The 3D-printed hubcap according to any one of claims 2 to 4, characterized in that, The rigidity of the subframe (2) is controlled by adjusting the structural parameters of the three-dimensional network structure, so that the first rigidity is greater than the second rigidity; the structural parameters include at least one of the following: the average number of connecting rods (21) directly connected to each connecting node (22), the average diameter of each connecting rod (21), and the average length of each connecting rod (21).

6. The 3D printed hub cap according to claim 5, characterized in that, The root of the mounting buckle (16) is integrally formed with the main frame (1), and its main body protrudes outward along the radial direction of the hub; the outer surface of the protruding part of the mounting buckle (16) is provided with anti-slip texture (18), and the inner surface is provided with reinforcing ribs (17).

7. The 3D printed hub cap according to claim 5, characterized in that, The display block (29) has an identification configuration and is integrally formed with the main three-dimensional network structure of the sub-frame (2) by 3D printing.

8. The 3D printed hub cap according to claim 5, characterized in that, The display block (29) includes a flat substrate and an integrated logo configuration on the substrate, which is integrally formed in the center of the three-dimensional network structure of the sub-frame (2) by 3D printing.

9. The 3D printed hub cap according to claim 3, characterized in that, The cross-sectional area of ​​the outer support ring (11) is defined as S1, the cross-sectional area of ​​the inner support ring (12) is defined as S2, and the average cross-sectional area of ​​each connecting rod (21) in the three-dimensional network structure of the sub-frame (2) is defined as S3, satisfying the relationship: (S1+S2) / S3=4.0~22.

5.

10. The method for manufacturing a 3D-printed wheel hub cap according to any one of claims 1-9, characterized in that, Includes the following steps: S1. Establish a three-dimensional digital model of the hub cover; S2. Using selective laser sintering technology, the molding material is integrally printed based on the three-dimensional digital model to obtain the wheel hub cover blank; S3. Post-process the hub cover blank to remove residual powder and obtain the 3D printed hub cover. The molding material is selected from PA11, PA12, glass fiber reinforced PA12, or PEEK.

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