Additive Part Section Joining With Integral Locating Features
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Solution Overview
Problem
Additive manufacturing is limited in producing large-sized parts due to size constraints of the build volume, and existing methods struggle to maintain high surface quality and accurate joining of complex parts with aesthetic and non-aesthetic surfaces.
Innovation Solution
The method involves splitting complex parts into sections with integral locating and joining features, which are printed separately and then assembled using interlocking connectors and alignment features, allowing for precise alignment and locking without additional joining means, thus preserving surface integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If parts are manufactured in sections to exceed build volume limits, then part size is improved, but joining accuracy and surface quality deteriorate
Solution Approach 1:
The part is divided into multiple sections that can be manufactured separately within build volume constraints and then assembled. The segmentation includes integrating locating features (such as pins and holes) and joining features (such as interlocking connectors) directly into the sections during the additive manufacturing process, enabling accurate reassembly while maintaining surface quality on A-surfaces.
2Manufacturing precision
If locating and joining features are added separately after printing, then surface quality is improved, but manufacturing complexity and time increase
Solution Approach 1:
The locating features and joining features are merged with the main part geometry and manufactured simultaneously with the A-surface in a single additive manufacturing process. This integration eliminates separate post-processing steps for adding these features, reducing manufacturing complexity and time while preserving surface quality since the features are formed as integral parts of the A-surface geometry.
Data Source
AI summary
Systems and methods are provided for printing sections of a part with integral locating and joining features. A system for joining part sections of a part having at least two separate sections includes a locating feature and a joining feature. The locating feature includes structures integrally formed with the sections to locate them relative to one another. The joining feature includes structures integrally formed with the sections to lock the sections together.