3D Printed Plastic Automotive Part Integration
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Solution Overview
Problem
The existing methods for manufacturing plastic automobile parts are cumbersome, requiring separate molding, storage, and assembly of reinforcement and functional elements, leading to complex handling and high fixed costs for customization and spare parts production.
Innovation Solution
A method where a second plastic part is directly manufactured by three-dimensional printing onto a first part, eliminating the need for separate storage and assembly through a mechanical attachment zone with a three-dimensional network of ribs, allowing for material compatibility and flexibility in geometry and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate molding and storage of reinforcement and functional elements is used, then manufacturing precision and material compatibility are ensured, but device complexity and handling operations increase
Solution Approach 1:
The patent combines multiple separate parts (first part, reinforcement elements, functional elements) into a single integrated component manufactured by 3D printing. The 3D printed part incorporates reinforcing ribs and functional features directly in the printed structure, eliminating the need for separate molding and assembly operations.
Solution Approach 2:
The 3D printing process serves multiple functions simultaneously: it creates the base part geometry, integrates reinforcement structures, incorporates functional elements (such as mounting features, cable channels, sensor mounts), and achieves final assembly all in one manufacturing operation, replacing multiple specialized processes.
2Adaptability or versatility
If multiple molds are used for different parts, then manufacturing precision is maintained, but fixed costs for customization and spare parts increase
Solution Approach 1:
The 3D printing process allows easy modification of design parameters and geometry through digital model changes rather than physical mold changes. Customization is achieved by modifying CAD files and reprinting, enabling low-cost adaptation for different customer requirements and spare part variations.
Solution Approach 2:
The patent accepts reduced tooling longevity in exchange for extreme flexibility - 3D printed molds or fixtures can be easily replaced or modified digitally, making the system ideal for low-volume production and spare parts where traditional expensive, long-lived molds are not economical.
3Strength
If traditional assembly methods (gluing, welding, stapling) are used, then structural strength is achieved, but additional assembly steps and time are required
Solution Approach 1:
The reinforcement and functional elements are merged into the base part structure during the 3D printing process itself. Features such as reinforcing ribs, mounting tabs, and structural supports are printed as integral parts of the same continuous material deposit process, eliminating post-assembly operations.
Solution Approach 2:
All structural reinforcement and functional features are prepared in advance during the 3D printing process before the part is removed from the printer. The part arrives at the customer ready-to-use with all strength and functionality built-in, requiring no additional assembly steps.
Data Source
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AI summary
The invention relates to a method for producing a part (10) made of plastic material for a motor vehicle, said part (10) comprising at least one first section (12) to which at least one second section (14) is applied, in which the first section (12) is produced. The second section (14) of the part (10) made of plastic material is produced by three-dimensional printing directly onto the first section (12) of the part (10).