Additive-Made Threaded Component Using Blind Rivet Nut Inserts
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Solution Overview
Problem
Additively manufactured components often require post-processing to achieve standardized threads due to manufacturing tolerances, which can be challenging, especially with difficult-to-machine materials like nickel-based alloys or titanium, and existing solutions complicate the construction process with auxiliary components or unreliable thread quality.
Innovation Solution
An additively manufactured component with a fungiform receiving space that accommodates a blind rivet nut or thread sleeve, featuring a widened molding section and a cylindrical support section, allowing for true-to-gauge thread insertion and compression to secure the thread element with a radial compression bead, ensuring a press fit and axial positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If threads are directly additively manufactured, then manufacturing freedom is improved, but thread precision and standardization deteriorate due to process-caused manufacturing tolerances
Solution Approach 1:
The solution divides the component into two parts: the additively manufactured base component and a separately manufactured thread element (such as a blind rivet nut). This segmentation allows each part to be optimized independently - the base component maintains design freedom while the thread element provides precise, standardized threading.
Solution Approach 2:
A thread element acts as an intermediary between the additively manufactured component and standard threaded fasteners. This intermediary provides the true-to-gauge thread interface without requiring direct thread formation in the additive manufacturing process, resolving the precision issue while preserving design freedom.
2Manufacturing precision
If machining processing steps are used to generate threads, then thread standardization is improved, but manufacturing complexity and effort worsen especially with difficult-to-machine materials
Solution Approach 1:
The threading operation is extracted from the main component manufacturing process. Instead of machining threads directly into difficult-to-machine materials like titanium or nickel-based alloys, the thread element is manufactured separately using appropriate processes and then integrated into the additive manufactured component.
Solution Approach 2:
The thread element serves as a replaceable, pre-manufactured component that can be easily installed and replaced if needed. This approach is more economical than investing in specialized machining capabilities for difficult-to-machine materials, especially for components that may require replacement.
3Ease of manufacture
If conventional manufacturing methods with coolants and lubricants are used, then manufacturing processability is improved, but environmental contamination and cleaning effort worsen in sensitive sectors
Solution Approach 1:
The solution replaces conventional mechanical threading processes that require coolants and lubricants with an additive manufacturing approach combined with a press-fit thread element. This substitution eliminates the need for harmful chemical substances while maintaining manufacturing feasibility.
Solution Approach 2:
The additive manufacturing process used here produces components without requiring the extensive coolant and lubricant systems needed for conventional machining of threads. The process is cleaner by design, making it suitable for sensitive sectors like medical and aerospace where contamination must be minimized.
4Adaptability or versatility
If a claw retention device is used to hold a thread element, then thread element releasability is improved, but device complexity and construction steps worsen
Solution Approach 1:
The solution merges the retention function directly into the additive manufactured component structure itself. The receiving space with its widened molding section and cylindrical support section is integrated into the component geometry, eliminating the need for separate claw retention devices and reducing construction complexity.
Solution Approach 2:
The receiving space structure serves multiple functions: it provides geometric interlocking for retention, enables press-fit installation, and defines the final position of the thread element. This multi-functionality replaces the need for specialized retention mechanisms while maintaining the ability to securely hold the thread element.
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 solution enables the reliable and efficient integration of true-to-gauge threads in additively manufactured components, reducing the need for post-processing and minimizing the complexity of thread installation, while providing robust pull-out resistance and axial positioning of the thread element.
Implementation Method 1
the compression portion (26) is compressed in the axial direction so that a compression bead (27) is formed which radially expands and is received by the widened molding section (14)
Implementation Method 2
a compression bead (27) is formed which radially expands and is received by the widened molding section (14)
Implementation Method 3
The receiving space (12) is configured fungiform in an axial cross section... providing geometric interlocking for retention
Data Source
AI summary
A component bond out of an additively manufactured component out of metal or plastic material having an inner receiving space that is open on at least one side on a component opening, which is accessible from a component side and is configured fungiform in an axial cross section. The receiving space includes at least one widened molding section facing the component opening and at least one cylinder shaped support section facing away from the component opening, wherein a blind rivet nut or a blind rivet bolt are fastened in the receiving space by a compression bead of the blind rivet nut or of the blind rivet bolt extending into the molding section.