Additive Component Interfaces Using Scanned Tongue-and-Groove Profiles
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Solution Overview
Problem
Existing additive manufacturing (AM) techniques face challenges in efficiently producing complex, high-throughput structures with precise features and interfaces, leading to increased production costs and waste due to inflexible designs and high machining requirements.
Innovation Solution
A method combining high-throughput, lower precision additive manufacturing with higher precision techniques, using a tongue-and-groove structure and optical scanning to create customized interfaces, allowing for precise mating and adhesive application between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-throughput additive manufacturing is used to produce large components, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The component is divided into two parts: a first component manufactured by high-throughput additive manufacturing and a second component manufactured by high-precision additive manufacturing. The first component contains a first feature while the second component contains a second feature that interfaces with the first feature, allowing each component to be optimized for its specific manufacturing requirements.
Solution Approach 2:
Different manufacturing processes are applied to different parts of the overall structure. The first component is produced using high-throughput additive manufacturing for areas where speed is critical, while the second component is produced using high-precision additive manufacturing for areas requiring accurate surface profiles and tight tolerances for interfacing.
2Manufacturing precision
If conventional manufacturing techniques are used to produce complex structures with precise features, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The invention changes the manufacturing parameters by selecting different additive manufacturing processes for different components. Instead of using conventional machining for both components, the solution uses high-precision additive manufacturing specifically for the second component where precision is critical, thereby maintaining precision while improving overall productivity.
3Ease of manufacture
If conventional manufacturing processes are used to create simple internal designs, then ease of manufacture is improved, but adaptability deteriorates
Solution Approach 1:
The first component is designed with a simple internal design that is easy to manufacture using high-throughput additive manufacturing, while the second component is designed with a complex internal design that requires high-precision additive manufacturing. This allows each component to be optimized for its specific manufacturing requirements while maintaining overall design flexibility.
Data Source
AI summary
Methods for joining components, and apparatuses comprising components to be joined, are described. An apparatus in accordance with an aspect of the present disclosure comprises a first component comprising a first feature having a first surface profile, and an additively-manufactured second component comprising a second feature having a second surface profile, wherein the second surface profile is generated at least in part from the first surface profile of the first interface, such that the first surface profile is configured to mate with the second surface profile.