3D-Printed Aerodynamic Seals for Complex Surface Geometry
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Solution Overview
Problem
Current aerodynamic seal manufacturing methods struggle to adapt to complex geometries, leading to suboptimal aerodynamic performance, increased weight, and high manufacturing and maintenance costs, due to the use of constant geometry seals and complex moulds required by traditional extrusion and injection moulding techniques.
Innovation Solution
The method employs 3D printing using vulcanised thermoplastic elastomers, allowing for the design and production of seals with variable geometries, enabling better adaptation to complex surfaces, reduced weight, and lower costs through additive manufacturing techniques like FDM, PE, and SLS, which facilitate geometric and functional optimisation, and allow for in-situ production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional extrusion or injection moulding methods are used to manufacture aerodynamic seals, then production costs are reduced for high-volume manufacturing, but the seals have constant geometry that cannot adapt to complex surfaces with double curvature
Solution Approach 1:
The patent replaces traditional mechanical moulding systems (extrusion and injection moulding) with a 3D printing system that uses digital models to directly manufacture seals with variable cross-sections. This substitution eliminates the need for complex physical moulds while enabling adaptation to complex geometries with double curvature, as the digital design can be freely modified without retooling costs.
Solution Approach 2:
The patent enables continuous variation of the seal's cross-sectional parameters along its length by modifying the digital 3D model. This allows the seal geometry to be optimized for complex surfaces with double curvature, transitioning from constant geometry to variable geometry without increasing device complexity, as the parameter changes are achieved through software rather than physical mould modifications.
2Adaptability or versatility
If injection moulding is used to produce seals with variable profiles, then geometric adaptability is improved, but the cost increases due to the need for multiple moulds
Solution Approach 1:
The patent replaces the mechanical mould system with a digital manufacturing system using 3D printing. This substitution eliminates the need for multiple expensive moulds required for variable profile seals, as the variable geometry is achieved through digital model modification rather than physical mould changes, significantly reducing manufacturing costs while maintaining geometric adaptability.
Solution Approach 2:
The patent creates a universal manufacturing system where a single 3D printing setup can produce seals with any cross-sectional profile by simply changing the digital model. This multi-functionality replaces the need for multiple specialized moulds, enabling variable profile capability without increasing manufacturing cost, as the system can adapt to different geometries through software rather than hardware changes.
3Ease of manufacture
If constant geometry seals are used, then manufacturing is simplified and costs are reduced, but aerodynamic performance is suboptimal on complex surfaces
Solution Approach 1:
The patent enables continuous variation of the seal's cross-sectional parameters along its length by modifying the digital 3D model. This allows the seal geometry to be optimized for complex surfaces with double curvature, transitioning from constant geometry to variable geometry without increasing device complexity, as the parameter changes are achieved through software rather than physical mould modifications.
Solution Approach 2:
The patent applies local quality optimization by varying the seal's cross-sectional geometry at different positions along its length to match the local requirements of the complex surface. Each section of the seal can have optimized dimensions and shape tailored to its specific location on the aerodynamic surface, improving overall aerodynamic performance while maintaining manufacturing simplicity through digital design.
4Productivity
If complex moulds are used for serial production, then initial manufacturing capability is achieved, but modification and optimisation after flight tests is limited and frequent
Solution Approach 1:
The patent replaces mechanical moulds with a digital manufacturing system. This substitution enables rapid design modifications after flight tests by simply updating the digital 3D model and reprinting the seals, eliminating the lengthy and costly mould modification process. The system maintains serial production capability while dramatically improving adaptability to design changes.
Solution Approach 2:
The patent enables preliminary digital prototyping and testing before final production. Design modifications can be simulated and optimized in the digital model before manufacturing, allowing frequent iterations during development. After flight tests, modifications can be rapidly implemented by updating the digital model, preventing the need for physical mould changes and enabling continuous optimization.
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 results in improved aerodynamic performance, reduced manufacturing times and costs, and enhanced flexibility in design modifications, enabling better prototyping and adjustment throughout the development cycle, with the ability to introduce internal cavities and modulate mechanical properties for improved sealing and durability.
Implementation Method 1
The invention essentially comprises the following phases or sequential processes: manufacture of the aerodynamic seal by means of 3D printing
Implementation Method 2
manufacture of the aerodynamic seal by means of 3D printing, in particular by means of selective laser sintering (SLS) of a thermoplastic
Implementation Method 3
The invention essentially comprises the following phases or sequential processes: manufacture of the aerodynamic seal by means of 3D printing... heat treatment of the aerodynamic seal manufactured according to the previous steps
Data Source
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Figure 2A~2C
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AI summary
The present invention relates to a method for manufacturing an aerodynamic seal and the product thus obtained to be adapted to fixed aerodynamic surfaces, mobile aerodynamic surfaces or a combination of both, with complex geometries, comprising the steps of: selecting a suitable vulcanised thermoplastic elastomer to meet the requirements required for aerodynamic seals and the requirements of additive manufacturing by means of 3D printing techniques known as fused deposition modelling (FDM) or by means of pellet extrusion (PE) or by means of selective laser sintering (SLS).