Additive Manufacturing Unibody Vehicle Shell

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Solution Overview

Problem

Current manufacturing processes for vehicles are complex, labor-intensive, and expensive, requiring specialized tools and resulting in long lead times for producing new vehicle models, limiting flexibility and responsiveness to market demands.

Innovation Solution

The method involves additive manufacturing of a shell template with an interior and exterior surface, applying a reinforcing composite material, sectioning panels with predetermined shapes, and modifying edges through layer-by-layer printing to create a unitary structure, such as a vehicle unibody, which eliminates the need for customized tooling and allows for faster production and design changes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional assembly manufacturing is used, then vehicle production can be achieved through standardized processes, but the process becomes labor intensive, complex, and expensive with long lead times

Engineering Contradiction:

Improveproduction speedVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges multiple separate manufacturing operations (stamping, assembly, painting) into a single additive manufacturing process that produces the entire vehicle body as one integrated structure, eliminating the need for complex assembly lines and reducing manufacturing steps

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces traditional mechanical stamping tools, assembly equipment, and painting systems with an additive manufacturing system that builds the vehicle body layer by layer, eliminating the need for specialized mechanical tooling and reducing equipment complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If customized tooling is used for each vehicle model, then production accuracy can be maintained, but the lead time for launching new vehicle models increases significantly

Engineering Contradiction:

Improvevehicle production accuracyVSAvoidlead time for new vehicle models

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent changes the manufacturing approach from subtractive (stamping with fixed tools) to additive (layer-by-layer construction), allowing digital modification of design parameters without requiring new physical tooling, thus enabling rapid production of different vehicle models

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses digital 3D models as copies of the vehicle design to guide the additive manufacturing process, replacing the need for physical customized tooling for each vehicle model while maintaining manufacturing precision through digital accuracy

Inventive Principle:

Principle #26Copying

3Strength

If traditional stamping and assembly processes are used, then vehicle bodies can be produced with required strength, but the final structure is heavier and requires more materials

Engineering Contradiction:

Improvevehicle body strengthVSAvoidvehicle body weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies local quality by varying the density and material properties at different locations within the vehicle body structure, placing material only where structurally necessary to maintain strength while minimizing overall weight

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent utilizes composite materials with varying properties that can be deposited layer by layer, allowing optimization of strength-to-weight ratio by selecting materials and configurations specific to each region of the vehicle body

Inventive Principle:

Principle #40Composite materials

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 enables the production of ultra-lightweight structures with reduced lead times, increased manufacturing flexibility, and faster product development cycles, allowing for the creation of vehicle bodies and panels on demand, applicable beyond the automotive industry.

Implementation Method 1

additive manufacturing a shell template of the unitary structure in a layer-by-layer printing process

Methodology Applied

Scientific Effect3D Printing: 3D Printing

Implementation Method 2

applying a reinforcing composite material precursor to the exterior surface of the shell template comprising a resin and a plurality of fibers, and treating the reinforcing composite material precursor to generate a reinforced shell

Methodology Applied

Scientific EffectComposite Materials: Composite Materials

Data Source

PatentUS10022912B2Additive manufacturing of a unibody vehicle

Publication Date: 2018.07.17 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

Methods for manufacturing structures are provided. The methods include manufacturing a shell structure by additive manufacturing methods and sectioning panels with predetermined shapes from the shell structure. The panels are subsequently coupled to shell structure. Devices for performing various steps of the methods are also provided.