3D-Printed Insert Threads for Accurate Standard Fastener Openings

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Solution Overview

Problem

Additive manufacturing methods struggle with geometric deviations in producing standard threads, especially for materials like nickel base alloys or titanium, requiring costly post-processing to achieve accuracy, and are hindered by coolant use and chip removal in sectors like medical and aerospace.

Innovation Solution

The method involves additively manufacturing an insert thread in the component instead of a standard thread, using geometric corrections and energy adjustments to create a standard thread combination with a wire thread insert, allowing for precise thread formation without post-processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If standard threads are manufactured additively, then design freedom and manufacturing capability are improved, but geometric precision and surface quality deteriorate

Engineering Contradiction:

Improvedesign freedomVSAvoidthread accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The thread structure is divided into two segments: an additively manufactured insert thread with reduced precision requirements, and a post-processed wire thread insert that provides the final standard thread geometry. This segmentation allows each part to be optimized independently - the insert thread for manufacturing freedom and the wire thread for precision

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insert thread is manufactured additively in advance with preliminary dimensions that accommodate the wire thread insert. The insert thread serves as a pre-prepared substrate that guides and supports the subsequent installation of the wire thread insert, ensuring proper alignment and positioning before final thread formation

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If post-processing is applied to achieve thread accuracy, then manufacturing precision is improved, but production time and cost increase

Engineering Contradiction:

Improvethread accuracyVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The critical precision requirements are extracted from the main additive manufacturing process and transferred to the wire thread insert. By removing the demand for high precision from the additive process itself and concentrating it in the standardized wire thread component, the overall production time is reduced while maintaining accuracy

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The wire thread insert acts as an intermediary element that bridges the gap between additive manufacturing capabilities and standard thread requirements. It serves as a mediator that transforms the imprecise insert thread into a precise standard thread through its own standardized geometry and installation process

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If conventional thread manufacturing is used for difficult materials, then thread strength is improved, but manufacturing complexity and additional processing steps increase

Engineering Contradiction:

Improvethread strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The wire thread insert is designed to be self-installing into the additively manufactured insert thread. The insert thread geometry automatically guides the wire thread insert into proper positioning and orientation, eliminating the need for complex alignment fixtures or specialized installation equipment for difficult-to-machine materials

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables precise, cost-effective production of standard threads with reduced geometric deviations, eliminating the need for post-processing and avoiding coolant issues, suitable for materials like aluminum, titanium, and nickel base alloys.

Implementation Method 1

the additive manufacturing method of a component with a thread opening... converting the three-dimensional component drawing with the adapted dimensions into a layer model for the additive manufacturing and additive manufacturing of the three-dimensional component

Methodology Applied

Scientific EffectLaser melting: Laser

Data Source

PatentUS12421993B2Additively manufactured component with insert thread, manufacturing method for the same as well as component with wire thread insert installed in the insert thread

Publication Date: 2025.09.23 BOLLHOFF VERBINDUNGSTECHNIK GMBH

AI summary

Additive manufacturing method of a component with a thread opening and an insert thread at its radial inner wall, for a wire thread insert to form a standard thread. A 3D component drawing includes the thread opening and the insert thread arranged in there, which is defined byDH⁢C≥DHC⁢min=d+0.7⁢5×Ptan⁡(α2)D1⁢H⁢C≥D1⁢HC⁢min=d+0.1⁢2⁢5×Ptan⁡(α2)D1⁢H⁢C≤D1⁢HC⁢max=d+0.1⁢2⁢5×Ptan⁡(α2)+0.3⁢7⁢3×P-0.1⁢9⁢2×P1.2⁢1PH⁢C=(DHC⁢min-D1⁢HC⁢min)×1.6×tan⁡(α2)withd nominal diameter of the screw threadα flank angle of the screw threadP pitch of the screw threadDHC nominal diameter of the insert threadDHC min smallest nominal diameter of the insert threadD1HC core diameter of the insert threadD1HC min smallest core diameter of the insert threadD1HC max largest core diameter of the insert threadPHC pitch of the insert thread.Dimensions of the insert thread are adapted with correction factors. The drawing is converted with the adapted dimensions into a model for the component manufacturing.