3D Printed Vehicle Joints for Gap Fit-Up and Stress Relief
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Solution Overview
Problem
Automotive manufacturers face challenges in building safer, lighter, and more efficient vehicles due to gaps between mating parts, which can render joining methods unfeasible and introduce residual stresses, affecting the dimensional and manufacturing robustness of vehicle structures.
Innovation Solution
A method involving 3D printing of assembly adjustment members to fill gaps between nodes and adjoining components, allowing relative movement for subsequent processing operations, and using custom 3D printed interface members to secure nodes to components, enabling improved fit-up and structural connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional joining methods are used to connect vehicle components, then assembly is straightforward, but gaps between mating parts render joining methods unfeasible and introduce residual stresses
Solution Approach 1:
A 3D printed interface member is introduced as an intermediary component between the first and second components. This interface member is custom-designed and 3D printed to precisely fill the gap between mating parts, enabling feasible joining while eliminating residual stresses by achieving proper fit-up.
Solution Approach 2:
The invention changes the geometric parameters of the interface member through 3D printing to precisely match the specific gap dimensions measured between components. By customizing the interface member's dimensions based on actual measurements, the solution adapts to varying gap sizes and eliminates the precision-mass tradeoff.
2Reliability
If 3D printed interface members are used to fill gaps, then joining feasibility is improved, but assembly process complexity increases
Solution Approach 1:
The gap measurement and interface member design are performed as preliminary actions before final assembly. By measuring gaps upfront and 3D printing custom interface members in advance, the actual assembly process is simplified to just placing the pre-fitted interface member, reducing on-site complexity.
Solution Approach 2:
The system performs self-service through automated gap measurement and data-driven interface member design. The measurement system automatically provides dimensional data that feeds into the 3D printing process, reducing manual intervention and simplifying the overall assembly workflow.
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 the dimensional and manufacturing robustness of vehicles by optimizing component fit-up and reducing residual stresses, allowing for more efficient and robust vehicle assembly processes.
Implementation Method 1
3D printing an assembly adjustment member according to the gap based on the measuring, the assembly adjustment member being physically separate from the node
Data Source
AI summary
A method of assembling components of a vehicle is provided that includes locating a node relative to an adjoining component, measuring at least one geometrical feature of the node or the adjoining component, 3D printing an assembly adjustment member based on the measuring, and placing the assembly adjustment member proximate at least one of the node or the adjoining component. The assembly adjustment member is configured to allow relative movement between the node and the adjoining component for subsequent processing operations.