3D-Printed Repair Insert for Vehicle Body Surface Defects
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Solution Overview
Problem
Current vehicle body repair methods using body filler compositions are time-consuming and require significant skill, as they involve multiple layers and are prone to defects like pinholes and cracks, making it difficult to achieve a high-quality, defect-free finish.
Innovation Solution
A method utilizing layered manufacturing techniques to create a complementary object from scan data, formed from thermoplastic or UV-cured polymers, which is then secured to the vehicle exterior body surface to repair defects without the need for traditional filler layers and sanding, using devices like 3D printing to produce objects with specific properties and voids for inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional body filler compositions are used for vehicle body repair, then the repair process can address deformities such as holes and dents, but the process becomes time-consuming and requires considerable skill with multiple layers and curative steps
Solution Approach 1:
The repair solution is segmented into distinct functional components: a pre-formed filler object that addresses the defect geometry, and separate curable composition layers that provide surface finish. This segmentation allows the filler object to be prepared independently in advance, eliminating the time-consuming process of building up and curing multiple filler layers sequentially.
Solution Approach 2:
The filler object is formed in advance using layered manufacturing techniques before the actual repair process. This preliminary action creates a ready-to-apply structural component that eliminates the need for time-consuming on-site filler application and curing cycles, while maintaining high repair quality.
2Reliability
If multiple layers of body filler are applied to achieve a defect-free finish, then the quality of repair improves, but the complexity and cost of the repair process increases due to curative steps
Solution Approach 1:
The repair system separates the structural filling function (performed by the pre-formed object) from the surface finishing function (performed by curable composition layers). This segmentation reduces process complexity by eliminating the need for multiple curative steps on filler material, while maintaining high repair quality through the integrated design of the filler object with embedded fasteners and inserts.
Solution Approach 2:
The filler object is created using layered manufacturing (3D printing) which digitally copies the precise geometry needed to complement the defect. This digital copying approach ensures dimensional accuracy and eliminates the need for skilled manual shaping and multiple curing cycles required by traditional filler methods.
3Ease of manufacture
If traditional filler methods are used, then repair can be performed with conventional materials, but the process requires significant skill and is prone to defects like pinholes and cracks
Solution Approach 1:
The manual mechanical process of applying and shaping filler material is replaced with automated layered manufacturing technology. This substitution eliminates human skill variability and the mechanical defects (pinholes, cracks) associated with manual filler application, while making the repair process more accessible to technicians with less specialized training.
4Productivity
If layered manufacturing techniques are used to create custom filler objects, then repair efficiency and quality improve, but new equipment and methods must be implemented
Solution Approach 1:
The layered manufacturing device is positioned as a versatile tool that can create various filler objects for different defect types (dents, holes, scratches) using a single equipment platform. This multi-functionality justifies the equipment investment by enabling efficient repair of multiple defect categories without requiring specialized tools for each defect type.
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 efficient and high-quality vehicle exterior body repairs by producing dimensionally accurate objects that can be seamlessly integrated into the vehicle surface, reducing the complexity and cost associated with traditional repair methods while ensuring a smooth finish.
Implementation Method 1
The object is formed from the manufacturing data set with a layered manufacturing device. The object is formed of a thermoplastic or a UV cured polymer
Data Source
AI summary
A method for repairing a defect in a vehicle exterior body surface is provided that includes a scan data set being generated that corresponds to the dimensional surface boundaries of the defect. A manufacturing data set is created for an object at least in part complementary to the defect from the scan data. The object is formed from the manufacturing data set with a layered manufacturing device. The object is joined to the defect to repair the vehicle exterior body surface. An object is also provided formed of a thermoplastic or a UV cured polymer with a shape that is at least at least in part complementary to a defect vehicle exterior body surface. The object having a void therein with the shape configured to receive an insert or a fastener therein.