3D-Printed Endoskeleton Transport Structure With Modular Repairable Assembly
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Solution Overview
Problem
The use of additive manufacturing (AM) in transport structures has been limited to producing small-scale components, with untapped potential for larger and more sophisticated substructures due to constraints in build plate size, print speed, and precision.
Innovation Solution
The application of AM techniques such as Direct Metal Deposition (DMD) and Powder Bed Fusion (PBF) to print entire frames and bodies of transport structures, along with modular components that can be easily assembled, repaired, and upgraded, utilizing multi-aspect printing machines that integrate various manufacturing processes into a single unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to produce small-scale components, then manufacturing flexibility and complexity are improved, but production scale and efficiency remain limited
Solution Approach 1:
The transport structure is divided into modular components (frame, body, endoskeleton) that can be manufactured separately using additive manufacturing and then assembled. This segmentation enables each module to be optimized for AM production while maintaining overall system functionality and scalability.
Solution Approach 2:
The patent transitions from producing only small components to manufacturing entire large-scale transport structures by utilizing the z-dimension (vertical build capability) of additive manufacturing systems, allowing complex 3D geometries to be produced directly without traditional tooling constraints.
2Productivity
If traditional manufacturing methods are used for transport structures, then production speed and cost are maintained, but design flexibility and customization capability are limited
Solution Approach 1:
Design modifications and customizations are performed in the digital CAD model stage before manufacturing, allowing rapid iteration and optimization without requiring physical tooling changes. This preliminary digital action enables flexible design changes while maintaining efficient production timelines.
Solution Approach 2:
The patent utilizes variable build parameters (layer thickness, infill density, support structures) in additive manufacturing to optimize both production efficiency and design flexibility, allowing the same manufacturing system to produce diverse configurations by changing process parameters rather than physical tooling.
3Device complexity
If entire frames and bodies are printed using additive manufacturing, then structural complexity and integration are improved, but build time and manufacturing precision requirements increase
Solution Approach 1:
The transport structure is divided into modular components (frame, body, endoskeleton) that can be manufactured separately using additive manufacturing and then assembled. This segmentation enables each module to be optimized for AM production while maintaining overall system functionality and scalability.
Solution Approach 2:
The patent employs continuous manufacturing processes and automated assembly operations to minimize idle time between printing and assembly stages, maintaining continuous productive action throughout the manufacturing workflow to reduce overall build time.
4Ease of repair
If modular components are assembled into the 3-D printed frame, then ease of repair and customization are improved, but assembly complexity and interface requirements increase
Solution Approach 1:
The patent employs standardized interfaces and mounting features that enable universal assembly of different modular components onto the frame. These universal interfaces simplify repair and customization operations while the modular design itself enables easy replacement of individual components without affecting the entire structure.
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
Enables the production of complex, large-scale transport structures with enhanced efficiency, modularity, and flexibility, allowing for easier repair, customization, and recycling, while reducing production time and costs.
Implementation Method 1
DMD is an AM technology that uses a laser to melt metallic powder and thereby transform it into a solid metal object
Implementation Method 2
Other AM processes such as powder bed fusion (PBF) use a laser to sinter or melt powdered material, which then bonds the powder particles together in targeted areas to produce a 3-D structure
Data Source
AI summary
Some embodiments of the present disclosure relate to an additively manufactured transport structure. The transport structure includes cavities into which components that use an external interface are inserted. A plurality of components are assembled and integrated into the vehicle. In an embodiment, the components and frame are modular, enabling reparability and replacement of single parts in the event of isolated failures.