Additive Manufacturing of Motor Vehicle Center Console with Embedded Routing
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Solution Overview
Problem
Manufactured components with embedded features, such as motor vehicle center consoles, often become bulky and overweight due to excess material and complex assembly, as they incorporate multiple system routing features like electrical wiring, duct work, and electronic modules, which are not optimized for weight and efficiency.
Innovation Solution
A method utilizing additive manufacturing techniques to define a boundary template, reserve space for embedded features, and structurally optimize components for efficient material distribution, allowing for the embedding of features like electrical wiring, duct work, and electronic modules within the component's material, thereby simplifying assembly and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional manufacturing methods are used to incorporate embedded features, then the component can contain multiple system routing features, but the component becomes bulky and overweight with excess material
Solution Approach 1:
The patent merges the component structure with embedded features (electrical wiring, duct work, electronic modules, antennas) by integrating them directly into the component body through additive manufacturing. This consolidation eliminates the need for separate components and assemblies, reducing overall weight while maintaining all required functions.
Solution Approach 2:
The patent utilizes the third dimension by embedding features within the volumetric structure of the component rather than attaching them to surfaces. Additive manufacturing enables routing systems through the interior volume of the component, allowing features to be positioned in three-dimensional space optimally, reducing material requirements and weight.
2Quantity of substance
If traditional manufacturing methods are used to incorporate embedded features, then the component can contain multiple system routing features, but the component requires complex assembly with additional components
Solution Approach 1:
The patent combines multiple separate components (housing, wiring harnesses, duct work, electronic modules, antennas) into a single integrated structure manufactured through additive manufacturing. This merger eliminates complex assembly operations and reduces the total part count while maintaining all system routing features.
Solution Approach 2:
The patent performs preliminary integration of all embedded features during the manufacturing process itself, rather than assembling them afterward. Additive manufacturing allows wiring, ducts, and modules to be built into the component structure during fabrication, eliminating subsequent assembly steps and reducing complexity.
3Quantity of substance
If traditional manufacturing methods are used, then the component can be produced, but the production process is less efficient and more costly
Solution Approach 1:
The patent merges multiple manufacturing operations into a single additive manufacturing process. Instead of separately producing the component body, wiring harnesses, duct work, and electronic module housings, all features are created in one integrated build process, significantly improving production efficiency and reducing costs.
Solution Approach 2:
The patent changes the manufacturing parameter from traditional subtractive or assembly-based methods to additive manufacturing. This parameter change enables direct digital fabrication of complex geometries with embedded features, improving production efficiency by eliminating tooling, fixtures, and multiple assembly operations.
Data Source
AI summary
A method of manufacturing a component with at least one embedded feature includes the steps of defining a boundary template for the component, reserving a functional region within the boundary template for the at least one embedded feature, consolidating and structurally optimizing the component to allow more efficient distribution of material and manufacturing the component using additive manufacturing techniques. A motor vehicle component including a motor vehicle center console are also disclosed.