Additive-Manufactured Components With Standard Thread Inserts
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Solution Overview
Problem
Additively manufactured components with directly manufactured threads often require reworking to achieve standard-compliant threads, which is challenging due to manufacturing tolerances and can be difficult with materials like nickel-based alloys or titanium, and existing solutions involve additional components or complex manufacturing processes that are not reliable.
Innovation Solution
An additively manufactured component with a mushroom-shaped receiving space that accommodates a blind rivet nut or threaded sleeve, featuring a widened molding section and cylindrical support section to securely house the threaded element, ensuring a true-to-gauge thread through a combination of deformation and form fit, preventing rotation and axial displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If threads are directly manufactured in additively manufactured components, then design freedom and manufacturing flexibility are improved, but thread precision and standard compliance deteriorate due to process-related manufacturing tolerances
Solution Approach 1:
The component is divided into two parts: the additively manufactured base component and a separately manufactured threaded element. The threaded element is inserted into a receiving space in the base component, allowing the thread to be manufactured separately with higher precision while the base component maintains design freedom from additive manufacturing.
Solution Approach 2:
A receiving space with a mushroom-shaped widened section acts as an intermediary structure. This receiving space accommodates the threaded element and provides deformation space during insertion, enabling the threaded element to be securely fixed while maintaining both design freedom and thread precision.
2Manufacturing precision
If machining operations are used to create threads in additively manufactured components, then thread standard compliance is improved, but manufacturing complexity and effort increase significantly for difficult-to-machine materials
Solution Approach 1:
The threading operation is separated from the additive manufacturing process. The threaded element is manufactured separately (potentially using conventional high-precision methods) and then inserted into the additively manufactured component, eliminating the need for complex machining of difficult-to-machine materials.
Solution Approach 2:
The threaded element is prepared in advance with its thread already formed to high precision. This preliminary action allows the thread to be created under optimal conditions before insertion, avoiding the need for post-additive-manufacturing machining operations.
3Ease of manufacture
If conventional thread manufacturing methods are used, then thread production is simplified, but contamination with cooling and lubricating substances occurs that requires additional cleaning equipment and time
Solution Approach 1:
The receiving space with its mushroom-shaped widened section serves as an intermediary that enables contamination-free thread insertion. The threaded element is inserted in a controlled manner into this receiving space, avoiding the need for cooling and lubricating substances that would contaminate the component.
Solution Approach 2:
The receiving space geometry itself facilitates the insertion and securing of the threaded element through its widened section that provides deformation space. This self-contained structure eliminates the need for external cooling and lubricating substances during the insertion process.
4Manufacturing precision
If auxiliary components like claws are used to provide threads in additively manufactured components, then thread provision becomes possible, but device complexity and number of manufacturing steps increase
Solution Approach 1:
The receiving space is integrated directly into the additively manufactured base component rather than being a separate auxiliary component. This merging of the receiving space with the base component reduces the number of separate parts and assembly steps while still providing the necessary functionality for thread insertion.
Solution Approach 2:
The receiving space with its mushroom-shaped widened section serves multiple functions: it provides the insertion path, accommodates the threaded element, provides deformation space during insertion, and contributes to securing the threaded element. This multi-functionality eliminates the need for separate auxiliary components like claws.
Data Source
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AI summary
A component assembly (A) consisting of an additively manufactured component (10) made of metal or plastic, which has an inner receiving space (12) open at least on one side at a component opening (11), which is accessible from one side of the component and is mushroom-shaped in an axial cross-section, wherein the receiving space has at least one flared molded section (14) facing the component opening and at least one cylindrical support section (16) facing away from the component opening, wherein a blind rivet nut (20) or a blind rivet stud (22) is fastened in the receiving space by means of a compression bead (27) of the blind rivet nut or blind rivet stud extending into the flared molded section (14).