3D-Printed Space Frame Joints for Variable Tube Geometry
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Solution Overview
Problem
Traditional methods for fabricating joints in space frame constructions, such as those used in vehicle chassis, are costly and inflexible, struggling to accommodate various geometric parameters and stress directions effectively.
Innovation Solution
A 3-D printing method that determines specific geometric and physical requirements for each tube intersection point, allowing for the creation of joints that accommodate relative tube angles, sizes, and shapes, while supporting stress directions and magnitudes, using a computer system and 3-D printer to generate custom joint members with centering features and internal routing for adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional fabrication methods are used for joint members, then manufacturing equipment and tooling costs are high, but the ability to accommodate various tube geometries and angles is limited
Solution Approach 1:
The patent employs additive manufacturing technology to fabricate joint members with varying geometric parameters including different tube angles, diameters, and wall thicknesses. The joint members can accommodate tubes with angles ranging from acute to obtuse and various cross-sectional shapes, all produced through digital modeling and 3D printing processes that allow rapid parameter adjustment without requiring physical tooling changes
Solution Approach 2:
The additive manufacturing process creates universal joint members that can serve multiple connection functions. A single manufacturing system can produce joint members for different tube configurations, materials (metal and composite), and structural requirements, eliminating the need for specialized equipment for each joint type and enabling one tool to perform many fabrication functions
2Ease of manufacture
If traditional fabrication methods are used for joint members, then manufacturing flexibility is reduced, but manufacturing costs may be lower for simple geometries
Solution Approach 1:
The patent replaces traditional mechanical fabrication systems (milling, machining, forming equipment) with additive manufacturing technology. This substitution enables the creation of complex joint geometries that would be difficult or impossible to produce with conventional methods, while reducing tooling costs and increasing design flexibility for both simple and complex structures
3Productivity
If 3-D printing is used to create custom joints for each tube intersection, then manufacturing costs and time are reduced, but the complexity of determining optimal joint configurations increases
Solution Approach 1:
The patent employs preliminary computational analysis to determine optimal joint configurations before the actual 3D printing process. Software tools calculate stress distributions, identify critical load paths, and optimize joint geometries in advance, allowing the additive manufacturing process to simply execute pre-determined designs rather than requiring real-time decision-making during production
Data Source
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AI summary
A method for fabricating a joint designed to connect tubes for a space frame, where a space frame may be a vehicle chassis, is provided. The method may generate joints with variable geometry and fine features which may reduce production costs, reduce production time, and generate joints configured for highly specific applications. The joint may include centering features which may create a space between a surface of the tube and a surface of the joint through which adhesive may flow.