3D-Printed Vehicle Components With Controlled Breaking Points
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Solution Overview
Problem
3D printing of vehicle components often results in parts with mechanical properties inferior to those manufactured using conventional methods, leading to potential mechanical failure and risk of damage to surrounding components upon failure, due to limitations in material strength and printing size constraints.
Innovation Solution
A method that determines and incorporates 'breaking points' into 3D models of vehicle components to ensure that upon failure, they do not contact nearby components, considering the physical boundaries, robustness, replacement cost, and safety assessment of surrounding components, thereby mitigating damage and optimizing failure direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If 3D printing is used to manufacture vehicle components, then production speed and design flexibility are improved, but mechanical strength and reliability deteriorate compared to conventional manufacturing
Solution Approach 1:
The patent modifies the 3D model parameters by determining breaking points and adjusting the design to account for material limitations in 3D printing. This allows the component to be optimized for additive manufacturing while maintaining adequate mechanical properties through parameter adjustments rather than exact copies of conventional designs.
Solution Approach 2:
The patent segments the vehicle component design by identifying breaking points that divide the component into sections. This segmentation allows the design to accommodate the layer-by-layer nature of 3D printing while managing stress distribution and mechanical integrity across different printed sections.
2Adaptability or versatility
If 3D printed components are used, then design flexibility is improved, but the risk of mechanical failure and damage to surrounding components increases
Solution Approach 1:
The patent applies preliminary anti-action by pre-determining breaking points in the 3D model before manufacturing. This proactive design approach anticipates potential failure points and structures the component so that if failure occurs, it happens in a controlled manner that prevents damage to surrounding components, thus counteracting the reliability issue before it manifests.
Solution Approach 2:
The patent performs preliminary analysis to identify breaking points and adjusts the 3D model accordingly before the actual printing process. This preliminary action ensures that the component is designed with failure safety built in from the outset, allowing design flexibility while mitigating reliability concerns through advance planning.
3Reliability
If breaking points are determined and incorporated into 3D models, then safety and control over failure behavior is improved, but manufacturing complexity increases
Solution Approach 1:
The system performs self-service by automatically determining breaking points and generating modified 3D models without requiring manual intervention. The processing unit autonomously analyzes the component geometry, identifies potential failure points, and adjusts the model accordingly, reducing the complexity burden on the manufacturing process while maintaining high reliability.
Solution Approach 2:
The patent incorporates feedback mechanisms where the determined breaking points and surrounding component information are used to iteratively refine the 3D model. This feedback loop ensures that the final design optimally balances failure safety with manufacturing feasibility, managing complexity through systematic refinement rather than trial and error.
Data Source
AI summary
An arrangement and a computer implemented method for three-dimensional (3D) printing of at least one first vehicle component (first VC) for a vehicle is provided. The method includes receiving a request to form the first VC. The method includes obtaining a 3D model for the first VC. The method includes identifying at least one second vehicle component located in proximity to the first VC when mounted on the vehicle. Also, the method includes determining at least one breaking point of the first VC which avoids the first VC to come into contact with the identified at least one second vehicle component in case the first VC should break at the at least one breaking point. The method includes forming a 3D model for the first VC based on the request and the determined at least one breaking point. The method includes instructing a 3D printer to print the 3D model.