3D Printed Components With Integrated Captive Fasteners
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Solution Overview
Problem
3-D printed components face challenges in secure and precise interconnection with other components due to manufacturing tolerance issues and limitations in complex geometries, especially in structural and nonstructural connections within mechanical structures like vehicles and aircraft.
Innovation Solution
The use of additively manufactured captive nuts, threaded shims, and pins with integrated anti-rotation features, along with retainer plates and inserts, allows for flexible and precise connections by co-printing or post-printing components with threads and shims to accommodate varying geometries and tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fastening methods are used with 3-D printed components, then assembly is straightforward, but manufacturing precision and tolerance control deteriorate due to additive manufacturing limitations
Solution Approach 1:
The fastening system is divided into separate components: 3-D printed body portions with integrated fastener receptacles, and separate fasteners (captive nuts, threaded inserts, pins). This segmentation allows each component to be optimized independently - the printed portions provide geometric flexibility while the separate fasteners ensure precise threading and connection characteristics that compensate for additive manufacturing tolerance variations.
Solution Approach 2:
Fasteners serve as intermediary elements between 3-D printed components. These intermediaries (captive nuts, threaded inserts, pins) absorb the tolerance mismatches that arise from additive manufacturing, providing a mechanical bridge that ensures precise and reliable connections between printed body portions while maintaining assembly simplicity.
2Adaptability or versatility
If complex geometries are printed directly, then design flexibility improves, but manufacturing precision deteriorates due to tolerance accumulation
Solution Approach 1:
The design is segmented into printed body portions that can achieve complex geometries and integrated fastener receptacles, while the actual fastening function is handled by separate precision fasteners. This allows the printed portions to focus on geometric flexibility and form factor without bearing the full burden of precision requirements, as the separate fasteners compensate for tolerance variations.
Solution Approach 2:
The patent changes the approach to precision by moving critical dimensional parameters from the additive manufacturing process to the fastener components. Instead of requiring the 3-D printer to achieve tight tolerances for all features, the design transfers precision requirements to the fasteners, which can be manufactured with higher precision using traditional methods, thereby maintaining design flexibility while controlling tolerance accumulation.
3Productivity
If captive fasteners are integrated into printed components, then assembly efficiency improves, but device complexity increases due to additional printing requirements
Solution Approach 1:
The fastening system is segmented such that fasteners are separate components rather than fully integrated into the printed part. This segmentation allows fasteners to be manufactured separately with higher precision using traditional methods, then assembled into the printed components. The result is simplified printing processes (no complex in-situ fastener formation) while maintaining assembly efficiency through pre-configured fastener receptacles and captive fastener arrangements.
Solution Approach 2:
Fasteners are prepared and positioned in advance during the printing process or immediately before assembly. Captive nuts and threaded inserts are either printed as separate components ready for installation or pre-positioned in receptacles during printing. This preliminary preparation of fasteners ensures they are ready for immediate installation, improving assembly efficiency without requiring complex integrated fastener formation within the printed part itself.
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 solution enables robust, flexible, and precise interconnections that address manufacturing tolerance issues and complex geometries, enhancing the structural integrity and assembly efficiency of 3-D printed components in mechanical structures.
Implementation Method 1
The 3-D printer may then bond particular areas of the powder layer into a layer of the object, e.g., by using a laser to bond the powder of the powder layer together.
Data Source
AI summary
One aspect is an apparatus including an additively manufactured first component and a captive nut contained within the first component for interconnecting the first component to a second component. Another aspect is an apparatus including a first additively manufactured component having a hole and a second additively manufactured component having a socket. The apparatus further includes a pin having a head engaging a surface of the first component and a shaft extending from the head through the hole in the first component and into the socket of the second component. Another aspect is an apparatus including first and second panels. The apparatus also includes a bolt having a head and a shaft extending from the head and a nut located at a distal end of the shaft. The first and seconds panels may be sandwiched between the bolt and nut to interconnect the first and second panels.