Method for manufacturing an assembly

Abstract

A method for manufacturing an assembly is proposed. The method comprises forming a first partial volume of the assembly from a plastic material using an additive manufacturing process. This first partial volume comprises several layers of the plastic material and at least one cavity formed therein for inserting a pre-fabricated insert. Furthermore, the method comprises continuing the additive manufacturing process after inserting the respective insert into the at least one cavity to form a second partial volume of the assembly from the plastic material. This continuation of the additive manufacturing process involves forming one or more further layers of the plastic material on the first partial volume. The one or more further layers of the plastic material at least partially cover the respective inserted insert.

Description

[0001] The present invention relates to a method for producing an assembly by means of additive manufacturing.

[0002] Additive manufacturing enables both the production of prototypes and series production without injection molding tools. An example additive multi-material 3D printing process for printing current guides made of conductive material with electrically insulating material interposed between them is described in DE 10 2020 215 608 A1. Known additive manufacturing processes have various disadvantages, such as a limited selection of printable materials, low durability of the manufactured part, low precision of the manufactured part, etc.

[0003] It is therefore an object of the present invention to provide an improved method for producing an assembly by means of additive manufacturing.

[0004] This object is achieved by a method for producing an assembly according to the independent claim. Advantageous further developments are specified in the dependent claims, the following description, and the figures.

[0005] According to a first aspect, the present invention relates to a method for producing an assembly. The method comprises forming a first partial volume of the assembly from a plastic material by means of an additive manufacturing process (3D printing process). The first partial volume comprises a plurality of layers of the plastic material and at least one cavity formed therein for introducing a respective prefabricated insert. A partial volume is generally a subset or a partial section or partial region of the entire assembly (to be manufactured). Furthermore, the method comprises continuing the additive manufacturing process after introducing the respective insert into the at least one cavity to form a second partial volume of the assembly from the plastic material. The respective insert is generally a prefabricated part or a prefabricated component that is inserted oris used to fulfill a specific function or task within the assembly (to be manufactured). In other words: the respective insert is not additively manufactured as part of the additive manufacturing process, but is already ready to be inserted or used. The respective insert can be selected depending on the type of assembly. The continuation of the additive manufacturing process comprises forming one or more further layers of the plastic material on the first partial volume. The one or more further layers of the plastic material at least partially cover the respective inserted insert and form the second partial volume of the assembly. The additive manufacturing of the assembly can be completed with the formation of the second partial volume of the assembly. Alternatively, one or more further partial volumes of the assembly can be formed iteratively.

[0006] Using the method according to the invention, the assembly can be manufactured without any further assembly steps. In particular, no melt lines are required in the plastic for, for example, gluing, screwing, or clipping the individual sub-volumes or inserts. The method according to the invention enables, in particular, near-series construction of the assembly or series production of the assembly. Using the method according to the invention, assemblies with an increased service life can be obtained compared to conventional additive manufacturing processes. Likewise, a variety of plastic materials can be used for the method according to the invention. The method according to the invention can be used in particular for the additive manufacturing (3D printing) of plastic insulation assemblies into which prefabricated busbars and / or other metal parts (e.g. sleeves) are inserted during interruptions in the additive manufacturing process.However, the present invention is not limited to this. Other types of assemblies can also be manufactured using the method according to the invention.

[0007] According to embodiments of the present invention, the method comprises interrupting the additive manufacturing process after forming the first partial volume of the assembly and inserting the respective insert into the at least one cavity. In other words, the first partial volume and the second partial volume are not additively manufactured independently of one another; rather, the additive manufacturing process for producing the first partial volume, the second partial volume, and possibly further partial volumes is interrupted only for the insertion of the respective insert.

[0008] In some embodiments of the present invention, the method additionally comprises preheating the respective insert part before introduction into the at least one cavity in order to improve adhesion of the respective insert part to the plastic material of the first partial volume of the assembly forming the at least one cavity. For example, the respective insert part can be heated to a temperature similar to a temperature of the plastic material of the first partial volume or a temperature of a production bed on which the assembly is additively manufactured. The respective insert part can be preheated for several minutes (e.g. 5 minutes), for example to 160°C or any other suitable temperature. The preparation of the respective insert part can also optionally comprise further processes such as cleaning (in particular degreasing) and drying the respective insert part before preheating.

[0009] As already indicated above, the additive manufacturing of the assembly can be completed with the formation of the second partial volume of the assembly. Alternatively, further partial volumes of the assembly can be formed iteratively. For example, according to embodiments of the present invention, the second partial volume of the assembly can comprise at least one further cavity for introducing a respective further prefabricated insert. Accordingly, according to embodiments of the present invention, the method then further comprises a renewed continuation of the additive manufacturing process after introducing the respective further insert into the at least one further cavity to form a third partial volume of the assembly from the plastic material. The renewed continuation of the additive manufacturing process comprises forming one or more further layers of the plastic material on the second partial volume.The one or more additional layers of the plastic material at least partially cover the respective additional inserted insert. In other words, the method comprises interrupting the additive manufacturing process after forming the second partial volume of the assembly and inserting the respective additional insert into the at least one additional cavity. By interrupting the additive manufacturing process for the insertion of one or more respective inserts into the last additively manufactured partial volume, the assembly can be finalized. Even complex geometries with a large number of inserts can be produced by interrupting the additive manufacturing process.The accumulated thickness of the layers of plastic material between the at least one insert inserted into the first sub-volume and the at least one further insert inserted into the second sub-volume can be selected depending on the desired properties of the assembly and the properties of the plastic material (e.g., 1.5 mm). For example, a lower material thickness may be sufficient for a plastic material with a higher dielectric strength and a higher volume resistivity than for a plastic material with a lower dielectric strength and a lower volume resistivity.

[0010] As already indicated above, the first partial volume can have a plurality of cavities. In some embodiments of the present invention, the first partial volume comprises at least two cavities for introducing the respective prefabricated insert. Between adjacent cavities of the at least two cavities, a separating region made of the plastic material (i.e., a volume made of the plastic material separating the two adjacent cavities) is formed. The formation of the one or more further layers of the plastic material on the first partial volume during the continuation of the additive manufacturing process, in these embodiments of the present invention, comprises a line-by-line formation of the one or more further layers of the plastic material.In at least the first of the one or more further layers, lines made of the plastic material are formed on at least part of the respective separating region, said lines running parallel to the extension of a side wall formed by the respective separating region of one of the cavities adjacent to the respective separating region. The respective separating region can be covered completely, essentially completely (e.g. more than 90%, 95% or 99%) or only partially with lines running parallel to the extension of the side wall formed by the respective separating region. Forming the lines parallel to the extension of the side wall formed by the respective separating region allows improved electrical insulation between the cavities adjacent to the respective separating region and thus the inserts introduced therein.In other words: Leakage currents between the cavities adjacent to the respective separation area and thus the inserts inserted therein can be minimized by forming the lines parallel to the extension of the side wall formed by the respective separation area. Small air gaps remain between the individual lines through which leakage currents can flow. By forming the lines parallel to the extension of the side wall formed by the respective separation area, the air gaps between the individual lines also run parallel to the extension of the side wall formed by the respective separation area. Accordingly, the gaps do not extend from one cavity to the other, thereby reducing leakage currents. In other words: The lines run essentially perpendicular to the shortest creepage distance for currents between the cavities. According to the invention, high-voltage-resistant assemblies can also be manufactured in this way.

[0011] For example, several further layers of the plastic material can be formed on the first partial volume as the additive manufacturing process continues. In these exemplary embodiments of the present invention, lines made of the plastic material are formed in at least the first two of the several further layers on at least a part of the respective separation region, said lines running parallel to the extension of a side wall formed by the respective separation region of one of the cavities adjacent to the respective separation region. By forming the lines parallel to the extension of the side wall formed by the respective separation region in at least the first two layers, the electrical insulation between the cavities adjacent to the respective separation region and thus the inserts introduced therein can be further improved.

[0012] According to some embodiments of the present invention, the lines that run parallel to the extension of a side wall formed by the respective separation region of one of the cavities adjacent to the respective separation region are formed at a first speed, and at least some of the other lines of the one or more further layers are formed at a second speed that is higher than the first speed. Forming the lines that run parallel to the extension of a side wall formed by the respective separation region of one of the cavities adjacent to the respective separation region at a lower speed enables a reduction or minimization of air gaps between the individual lines. The electrical insulation between the cavities adjacent to the respective separation region and thus the inserts introduced therein can thereby be further improved.

[0013] In some embodiments of the present invention, a plurality of further layers of the plastic material are formed line by line on the first partial volume as the additive manufacturing process continues. In at least the first of the plurality of further layers, lines of the plastic material are formed above the respective insert part at a first speed, and another portion of the lines in the plurality of further layers are formed at a second speed that is higher than the first speed. By reducing the speed above the respective insert part, better adhesion of the plastic material to the respective insert part can be achieved. Accordingly, the stability and durability of the assembly can be improved. The lower speed also enables a reduction or minimization of air gaps between the individual lines.This allows the respective inserts to be better electrically insulated from each other.

[0014] According to some embodiments of the present invention, a plurality of further layers of the plastic material are formed line by line on the first partial volume as the additive manufacturing process continues. In at least the first of the plurality of further layers above the respective insert, lines of the plastic material are formed with a first line thickness, and another portion of the lines in the plurality of further layers are formed with a second line thickness that is stronger than the first line thickness. By reducing the line thickness above the respective insert, a reduction or minimization of air gaps between the individual lines can be achieved. The respective inserts can thus be better electrically insulated from one another.

[0015] The thickness of the individual layers can be selected depending on the desired properties of the assembly and / or the properties of the plastic material (e.g., between 0.5 mm and 5 mm). With a higher layer thickness, fewer layers are required to form the assembly or the respective sub-volume. This can lead to better dielectric strength and volume resistivity of the assembly or the respective sub-volume. With a lower layer thickness, more layers are required to form the assembly or the respective sub-volume. This can increase the accuracy of the assembly or the respective sub-volume.

[0016] The plastic material used in the additive manufacturing process can, for example, be pure plastic, fiber-reinforced plastic, plastic mixed with filler material (e.g. glass beads), or a combination thereof. The plastic can, in particular, be a thermoplastic such as polyphenyl sulfide (PPS). However, the present invention is not limited to this. Any other suitable plastic can also be used. The introduction of filler material or fiber reinforcements can improve both the mechanical and dielectric strength of the plastic material (e.g. more filler material or fiber reinforcements for more strength). For example, between 50% and 100% filler material or fiber reinforcements can be selected, depending on the desired dielectric strength of the plastic material. The proportion of filler material orFiber reinforcements in the plastic material can be changed once or multiple times during the additive manufacturing process in order to produce the assembly with one or more local variations in the composition of the plastic material. If a plastic insulation assembly is manufactured using the method according to the invention, a thermoplastic such as PPS with a glass fiber content (e.g. 20 to 45%) can be selected. In this way, a high dielectric strength of the thermoplastic material (e.g. > 10 kV / mm) and a high volume resistance (e.g. > 109 Ω*cm) can be achieved. Likewise, a good tracking index (e.g. 175 V to 600 V or insulation class IIIb) can be achieved and good flammability of the thermoplastic material (e.g. classes V0, V1, HB) can be ensured.

[0017] The respective insert can be diverse depending on the type of assembly being manufactured. For example, the respective insert can be selected from the following list: an electrical conductor (e.g. wires, stamped or cast conductors), a busbar or current rail (made of various materials such as gold, silver, steel or aluminum), a sensor (e.g. temperature or current sensor), a metallic reinforcement for the assembly, a sleeve or feedthrough, a bushing, a cable. Using the aforementioned inserts, for example, a wide variety of plastic insulation assemblies can be produced using the method according to the invention. However, the present invention is not limited to the aforementioned examples. Any other suitable insert can also be used.

[0018] According to a second aspect, the present invention relates to an assembly produced by the method according to the first aspect of the present invention. Accordingly, the assembly can have an increased service life compared to components manufactured using conventional additive manufacturing methods. For example, the assembly can be a plastic insulation assembly into which prefabricated busbars and / or other metal parts (e.g. sleeves) were inserted during interruptions in the additive manufacturing process. However, the present invention is not limited thereto. The assembly can also be any other type of assembly. For example, the assembly can be an inverter busbar, an AC filter unit with busbars, or a rotor position sensor. In general, the assembly can be any type of low-voltage assembly.

[0019] They show: Fig. 1 schematically shows an embodiment of a method for producing an assembly; Fig. 2 a plastic insulation assembly during various stages of the manufacturing process; Fig. 3 producing a layer over inserts; and Fig. 4 a detailed view of a portion of a layer produced over inserts.

[0020] Fig. 1 schematically shows an embodiment of a method 100 for producing an assembly, such as a plastic insulation assembly. The method 100 comprises forming 110 a first partial volume of the assembly from a plastic material by means of an additive manufacturing process. The first partial volume comprises a plurality of layers of the plastic material and at least one cavity formed therein for introducing a respective prefabricated insert. The method 100 further comprises interrupting 112 the additive manufacturing process after forming the first partial volume of the assembly and inserting 114 the respective insert into the at least one cavity in the first partial volume. The method 100 further comprises continuing 120 the additive manufacturing process after introducing the respective insert into the at least one cavity to form a second partial volume of the assembly from the plastic material.Continuing the additive manufacturing process involves forming one or more additional layers of the plastic material on the first partial volume. The one or more additional layers of the plastic material at least partially cover the respective inserted insert.

[0021] Analogous to the first partial volume, the second partial volume can comprise at least one further cavity for introducing a respective further prefabricated insert. Accordingly, the method 100 can comprise a renewed interruption 122 of the additive manufacturing process after forming the second partial volume of the assembly and an introduction 124 of the respective further insert into the at least one further cavity in the second partial volume. In this case, the method 100 comprises a renewed continuation 130 of the additive manufacturing process after introducing the respective further insert into the at least one further cavity to form a third partial volume of the assembly from the plastic material. The renewed continuation of the additive manufacturing process comprises forming one or more further layers of the plastic material on the second partial volume.The one or more further layers of the plastic material at least partially cover the respective further inserted insert.

[0022] The first, second and third partial volumes are not additively manufactured independently of each other, but the common (integral) additive manufacturing process for the production of the first, second and third partial volumes (and possibly further partial volumes) is only interrupted for the insertion of the respective insert.

[0023] According to method 100, the 3D printing process is thus first started and printing continues until, for example, a cavity for a busbar is completely created. The printing temperature can be between 300°C and 400°C (e.g., 345°C) depending on the selected plastic material (e.g., PPS with or without fiber reinforcement or with or without filler material). The 3D printing process is then interrupted and the busbar is inserted into the cavity. The 3D printing process is subsequently restarted and printing continues until the next cavity for another busbar is complete. The 3D printing process is then interrupted again and the additional busbar is inserted into this cavity. The 3D printing process is subsequently restarted and the assembly is completed. The number of restarts of the 3D printing process according to method 100 is at least one and can theoretically be unlimited.

[0024] Fig. Figure 2 shows, by way of example, a plastic insulation assembly 200 during four different stages of the manufacturing method according to the invention. In sub-figure (a), the plastic insulation assembly 200 is shown in a first, earliest stage of the manufacturing method according to the invention. A first partial volume 210 of the plastic insulation assembly 200 was formed from a plastic material using an additive manufacturing process. The first partial volume 210 comprises several layers of the plastic material and has three cavities 221, 222, and 223 for inserting a respective busbar.

[0025] After forming the first partial volume 210, the additive manufacturing process is interrupted, and the respective busbar 231, 232, and 233 is inserted into each of the three cavities 221, 222, and 223. Partial figure (b) shows the plastic insulation assembly 200 after inserting the busbar 231, 232, and 233 into the three cavities 221, 222, and 223.

[0026] The additive manufacturing process then continues to form a second partial volume 240 of the assembly 200 from the plastic material. For this purpose, several additional layers of the plastic material are formed on the first partial volume 210 and also partially on the busbars 231, 232, and 233. Accordingly, the one or more additional layers of the plastic material partially cover the respective inserted insert 231, 232, or 233. This is evident from sub-figure (c).

[0027] The second partial volume 240 of the assembly 200 comprises a further cavity for the introduction of another prefabricated insert 250 in the form of a connecting part. In sub-figure (c), the insert 250 has already been introduced into the further cavity in the second partial volume 240.

[0028] After the insert 250 has been introduced into the further cavity in the second partial volume 240, the additive manufacturing process, which was interrupted for the introduction of the insert 250, is continued to form a third partial volume 260 of the assembly 200 from the plastic material. For this purpose, several additional layers of the plastic material are formed on the second partial volume 240 and also partially on the connecting part 250. Accordingly, the one or more additional layers of the plastic material partially cover the connecting part 250. This is evident from sub-figure (d). The third partial volume 260 forms the end of the plastic insulation assembly 200.

[0029] Fig. Figure 3 shows, by way of example, the production of the first layer 330 during the inventive formation of the second volume part of an assembly 300 on a first volume part 310 of the assembly 300. Partial figure (a) shows the first volume part 310. The first volume part 310 was formed from a plastic material using an additive manufacturing process. The first volume part 310 comprises several layers of the plastic material and has three cavities 321, 322, and 323 for inserting a respective insert.

[0030] The first layer 330 is formed line by line. Partial figure (b) now shows the beginning of the formation of the first layer 330. For reasons of clarity, the inserts introduced into the three cavities 321, 322, and 323 are not shown in parts (b) to (d). As can be seen from part (b), the edge 336 of the first layer 330 is first formed using additive manufacturing.

[0031] The three cavities 321, 322, and 323 are spaced or separated from one another in the first sub-volume 310 by a respective separation region 324, 325 made of the plastic material. The adjacent cavities 321 and 322 are separated from one another by the separation region 324, and the adjacent cavities 322 and 323 are separated from one another by the separation region 325. To further form the first layer 330, plastic material is now applied to all areas of the surface of the first sub-volume 310 as well as to the inserts introduced into the three cavities 321, 322, and 323—these are identified in sub-figure (c) by the reference numerals 331, 332, and 333. Only the separation regions 324 and 325 are initially not covered with plastic material.

[0032] Subsequently, lines of plastic material are also applied to the separation areas 324 and 325. The lines formed on the separation areas 324 and 325 are identified in sub-figure (d) with the reference numerals 334 and 335. The lines on the separation area 324 run parallel to the extension of the side wall formed by the separation area 324 of the cavity 321 adjacent to the separation area 324. The lines on the separation area 325 run parallel to the extension of the side wall formed by the separation area 325 of the cavity 322 adjacent to the separation area 325.

[0033] The lines in the areas 331, 332 and 333 run diagonally to the lines in the areas 334 and 335 of the first layer 330. This is in Fig. 4 for the regions 331, 332 and 334 are shown again in detail. The lines in the region 334 are formed on the separation region 324 and run parallel to the extension of the side wall formed by the separation region 324 of the cavity 321 adjacent to the separation region 324. The course of the side wall is shown in Fig. 4 is indicated by line 350. The lines in areas 331 and 332 run diagonally to the lines in area 334.

[0034] Forming the lines in the regions 334 and 335 parallel to the extension of the side wall formed by the respective separating region 324 or 325 allows improved electrical insulation between the cavities adjacent to the respective separating region 324 or 325 and thus the inserts introduced therein. In other words: leakage currents between the cavities adjacent to the respective separating region 324 or 325 and thus the inserts introduced therein can be minimized by forming the lines parallel to the extension of the side wall formed by the respective separating region 324 or 325. Small air gaps remain between the individual lines, through which leakage currents can flow. By forming the lines parallel to the extension of the side wall formed by the respective separating region 324 or 325, the gaps between the individual lines also run parallel to the extension of the side wall formed by the respective separating region 324 or 325.325 formed sidewall. Accordingly, the gaps do not extend from one cavity to the other, thereby reducing leakage currents. In other words, the lines run essentially perpendicular to the shortest creepage distance for currents between the cavities. According to the invention, high-voltage-resistant assemblies can also be manufactured in this way.

[0035] The lines in regions 334 and 335 are formed at a lower speed than the lines in regions 331, 332, and 333 in order to reduce or minimize air gaps between the individual lines. This further improves the electrical insulation between the cavities adjacent to the respective separation regions 324 and 325, and thus the inserts inserted therein.

[0036] By forming further layers on the layer 330, the second volume part of the assembly 300 can be completed.

[0037] Layer 330, as well as one or more layers formed immediately thereafter, can be formed at a lower speed and with a smaller line width than the remaining layers of the second volume portion of assembly 300. The lower speed and the reduced line width each enable a reduction or minimization of air gaps between the individual lines. Accordingly, better electrical insulation can be achieved. By reducing the speed in the first layers above the inserts, better adhesion of the plastic material to the respective insert can also be achieved. Reference symbol 100 Methods for Manufacturing an Assembly 110 Forming a first partial volume of the assembly 112 Interrupting the additive manufacturing process 114 Inserting the respective insert 120 Continuing the additive manufacturing process 122 further interruption of the additive manufacturing process 124 Inserting the respective additional insert 130 Resumption of the additive manufacturing process 200 plastic insulation assembly 210 first subvolume 221 cavity 222 Cavity 223 Cavity 231 busbar 232 busbar 233 Busbar 240 second partial volume 250 insert 260 third sub-volume 300 assembly 310 first partial volume 321 cavity 322 cavity 323 Cavity 324 Separation area 325 Separation area 330 first shift 331 Area of ​​the first layer 332 Area of ​​the first layer 333 Area of ​​the first layer 334 Area of ​​the first layer 335 Area of ​​the first layer 336 Edge of the first layer QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2020 215 608 A1

[0002]

Claims

[1] A method (100) for manufacturing an assembly, comprising: Forming (110) a first partial volume of the assembly from a plastic material by means of an additive manufacturing process, wherein the first partial volume comprises several layers of the plastic material and at least one cavity formed therein for introducing a respective prefabricated insert; and Continuing (120) the additive manufacturing process after introducing the respective insert into the at least one cavity to form a second partial volume of the assembly from the plastic material, wherein the continuation of the additive manufacturing process comprises forming one or more further layers of the plastic material on the first partial volume, wherein the one or more further layers of the plastic material at least partially cover the respective inserted insert. [2] The method (100) of claim 1, further comprising: interrupting (112) the additive manufacturing process after forming the first partial volume of the assembly; and Inserting (114) the respective insert into the at least one cavity. [3] The method (100) of claim 2, further comprising: Preheating the respective insert part before insertion into the at least one cavity in order to improve adhesion of the respective insert part to the plastic material of the first partial volume of the assembly forming the at least one cavity. [4] Method (100) according to one of claims 1 to 3, wherein the second partial volume of the assembly comprises at least one further cavity for introducing a respective further prefabricated insert, and wherein the method (100) further comprises the following: resuming (130) the additive manufacturing process after introducing the respective further insert part into the at least one further cavity to form a third partial volume of the assembly from the plastic material, wherein the resumption of the additive manufacturing process comprises forming one or more further layers of the plastic material on the second partial volume, wherein the one or more further layers of the plastic material at least partially cover the respective further inserted insert part. [5] Method (100) according to one of claims 1 to 4, wherein the first partial volume comprises at least two cavities for introducing the respective prefabricated insert, wherein a separation region made of the plastic material is formed between adjacent cavities of the at least two cavities, wherein the formation of the one or more further layers of the plastic material on the first partial volume during the continuation (120) of the additive manufacturing process comprises the following: line-by-line formation of the one or more further layers of the plastic material, wherein in at least the first of the one or more further layers on at least a part of the respective separation region, lines made of the plastic material are formed, which run parallel to the extension of a side wall formed by the respective separation region of one of the cavities adjacent to the respective separation region. [6] Method (100) according to claim 5, wherein a plurality of further layers of the plastic material are formed on the first partial volume during the continuation (120) of the additive manufacturing process, and wherein in at least the first two of the plurality of further layers, lines of the plastic material are formed on at least a part of the respective separation region, which lines run parallel to the extension of a side wall formed by the respective separation region of one of the cavities adjacent to the respective separation region. [7] Method (100) according to claim 5 or 6, wherein the lines which run parallel to the extension of a side wall formed by the respective separation region of one of the cavities adjacent to the respective separation region are formed at a first speed and at least some of the other lines of the one or more further layers are formed at a second speed which is higher than the first speed. [8] Method (100) according to one of claims 1 to 7, wherein a plurality of further layers of the plastic material are formed line by line on the first partial volume during the continuation (120) of the additive manufacturing process, wherein in at least the first of the plurality of further layers above the respective insert part, lines of the plastic material are formed at a first speed and another part of the lines in the plurality of further layers are formed at a second speed which is higher than the first speed. [9] Method (100) according to one of claims 1 to 8, wherein a plurality of further layers of the plastic material are formed line by line on the first partial volume during the continuation (120) of the additive manufacturing process, wherein in at least the first of the plurality of further layers above the respective insert part, lines of the plastic material are formed with a first line thickness and another part of the lines in the plurality of further layers are formed with a second line thickness which is stronger than the first line thickness. [10] The method (100) of any one of claims 1 to 9, wherein the plastic material is pure plastic, fiber-reinforced plastic, filled plastic, or a combination thereof. [11] Method (100) according to one of claims 1 to 10, wherein the respective insert part is selected from the following list: an electrical conductor, a busbar, a sensor, a metallic reinforcement for the assembly, a sleeve, a bushing, a cable.

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