3D Printed Springs With Integrated Strain Sensing

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Solution Overview

Problem

Conventional methods for creating springs lack integrated strain sensing capabilities, leading to increased complexity, weight, and cost due to the need for multiple electronic components and assembly steps.

Innovation Solution

3D printed springs with integrated strain sensing, utilizing multi-material 3D printing to combine conductive and insulative materials, allowing for deformation measurement through changes in electrical conductivity, thereby reducing the number of components and assembly steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple electronic components are added to springs for strain sensing, then strain sensing capability is achieved, but weight increases

Engineering Contradiction:

Improvestrain sensing capabilityVSAvoidspring weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The spring and strain sensor are merged into a single integrated component. The conductive material is embedded within the spring structure itself during manufacturing, eliminating the need for separate sensor components and their associated mounting hardware, thereby achieving strain sensing capability without significant weight increase

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electrical conductivity parameter of the spring material is changed by incorporating conductive materials during 3D printing. This parameter change enables the spring to function as a sensor without adding separate electronic components, thus maintaining weight efficiency while achieving strain sensing capability

Inventive Principle:

Principle #35Parameter changes

2Reliability

If multiple electronic components are added to springs for strain sensing, then strain sensing capability is achieved, but cost increases

Engineering Contradiction:

Improvestrain sensing capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The spring and strain sensor are manufactured as a single integrated component using multi-material 3D printing. This merging eliminates the need for separate procurement, assembly, and testing of multiple electronic components, thereby reducing manufacturing cost while achieving strain sensing capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductive material is embedded into the spring structure during the initial 3D printing manufacturing process rather than adding sensors afterward. This preliminary integration of sensing capability into the manufacturing step reduces overall production complexity and cost

Inventive Principle:

Principle #10Preliminary action

3Reliability

If multiple electronic components are added to springs for strain sensing, then strain sensing capability is achieved, but assembly steps increase

Engineering Contradiction:

Improvestrain sensing capabilityVSAvoidassembly steps

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The spring and strain sensor are merged into a single integrated component that is manufactured as one piece using multi-material 3D printing. This eliminates the need for separate assembly steps to attach sensors to the spring, thereby achieving strain sensing capability without increasing assembly complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sensing functionality is built into the spring during the initial manufacturing process through multi-material 3D printing. This preliminary integration means that no subsequent assembly steps are required to add sensing components, maintaining high productivity

Inventive Principle:

Principle #10Preliminary action

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

The 3D printed springs provide efficient energy return and strain sensing capabilities, reducing weight and cost while simplifying assembly and component count by utilizing integrated strain sensing technology.

Implementation Method 1

The second 3D printed material has an electrical conductivity that is greater than an electrical conductivity of the first 3D printed material. The spring is configured to have an electrical conductivity between the first and second electrical contacts that changes in response to deformation of the spring.

Methodology Applied

Scientific EffectElectrical Conductivity: Conduction (electrical)

Implementation Method 2

Elastic deformations of the spring can be detected by measuring the electrical conductivity of the second material.

Methodology Applied

Scientific EffectPiezoresistive Effect: Piezoresistive Effect

Data Source

PatentUS11877937B2Springs with strain feedback

Publication Date: 2024.01.23 ACCENTURE GLOBAL SOLUTIONS LTD

AI summary

Springs can provide energy return and have a conductivity that changes in relation to an amount of strain or deformation of the spring. In some embodiments, the springs are made by multi-material 3D printing (additive manufacturing). Such springs made by multi-material 3D printing may include a first material that is electrically non-conductive and a second material that electrically conductive. The extent of deformation or strain of the spring may be determined or estimated by measuring the conductivity or resistivity of the electrically conductive material portion of the spring.