3D Printed Thread Former with Multi-Material Profile Body
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Solution Overview
Problem
Existing thread formers or thread drills face challenges in meeting diverse operational requirements due to the complexity and reliability issues of soldering wear-resistant strips, which can lead to detachment and inability to adapt to varying material needs across the profile body.
Innovation Solution
The thread former or thread drill is constructed using 3D printing technology, allowing for the creation of sections made from different materials, which are integrally connected and adapted to specific operational requirements, with cutting edges or pressure edges introduced to produce threads, and the shank body can be clamped for rotary driving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If strips of wear-resistant material are soldered onto the profile body, then the service life of the tool is increased, but the production process becomes complex and the strips may detach during operation
Solution Approach 1:
The patent merges the wear-resistant strips with the profile body by integrating them into a single sintered component. Different materials (tool steel and hard metal) are combined in one sintering process to form an integral structure where the hard metal sections are permanently bonded to the tool steel profile body, eliminating the detachment risk associated with soldered strips.
Solution Approach 2:
The patent uses composite materials by combining tool steel and hard metal in a single component. The profile body is made of tool steel while specific sections (thread grooves, cutting edges) are made of hard metal. This composite structure is achieved through selective sintering, creating a unified component with spatially varying material properties that provides both strength and wear resistance.
2Duration of action of stationary object
If the entire profile body is made from wear-resistant material, then the service life is increased, but the production cost increases significantly
Solution Approach 1:
The patent applies local quality by providing wear-resistant hard metal only in specific sections where it is most needed (thread grooves, cutting edges, pressure edges) while the rest of the profile body is made of less expensive tool steel. This localized application of expensive material optimizes the balance between service life and production cost.
3Reliability
If soldering strips onto the profile body is used, then wear resistance is improved in specific areas, but the production process becomes complex and flexible
Solution Approach 1:
The patent merges multiple production steps into one by combining the formation of the profile body and the integration of hard metal sections into a single sintering process. This eliminates the separate soldering step required in conventional methods, simplifying production technology while maintaining wear resistance.
4Ease of manufacture
If conventional production methods are used for the profile body, then manufacturing is simpler, but flexibility in adapting to different operational requirements is reduced
Solution Approach 1:
The patent uses parameter changes in the sintering process to achieve different material properties in different sections of the profile body. By controlling sintering parameters (temperature, atmosphere, time) and material composition during the building process, the invention can create sections with varying hardness, density, and material composition to meet different operational requirements.
Solution Approach 2:
The patent adds material composition as an additional dimension of variability in the profile body design. Instead of relying solely on geometric variations, the invention enables spatial variation of material properties (different metals, alloys, or composites) throughout the profile body, providing enhanced adaptability to different operational requirements.
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 approach enhances operational reliability and flexibility, allowing for optimal adaptation of different sections to meet diverse requirements without the risk of detachment, enabling the production of threads with high precision and torque transmission.
Implementation Method 1
material is applied in layers in a mold and by selective melting or sintering of the material that is applied at least the profile body of the thread former or - drill is built up
Implementation Method 2
by selective melting or sintering of the material that is applied at least the profile body of the thread former or - drill is built up
Data Source
Figure 1~4
Figure 5
AI summary
The invention relates to a thread former or drill comprising a shank body having a clamping section at one end and a profile body for forming or cutting a thread at the other end, wherein at least the profile body has been built up layer by layer in a 3D printing process, with at least two sections (26, 28) of the profile body consisting of different materials (16, 18, 20, 26, 28) being produced. The invention further relates to a method for manufacturing such a thread former or drill.