Additive Manufacturing Joiners for Multi-Material Bonding
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Solution Overview
Problem
Current additive manufacturing methods face challenges in effectively fastening multiple materials together during the build process, fixing parts during printing, integrating multiple build technologies, and enhancing end-part properties, particularly due to limitations in interlayer bonding and compatibility between different materials.
Innovation Solution
The development of a joiner system that uses an anchor of a second material bulk deposited by an additive manufacturing tool head into a receptacle in a body of a first material, with an optional anchor layer deposited on top, to create strong and material-independent bonds between different materials and layers, allowing for improved reinforcement and separation of printed parts from the build platform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional assembly line manufacturing is used, then high volume production of standardized products is achieved, but manufacturing complexity and assembly steps increase
Solution Approach 1:
The patent merges multiple manufacturing operations into a single integrated AM build process. Components that would traditionally be manufactured separately and assembled are instead produced as integrated structures with built-in joiners, eliminating assembly line complexity while maintaining productivity.
Solution Approach 2:
The patent segments the manufacturing process into modular components with standardized joiner interfaces. This allows independent manufacturing of components that are then automatically joined during the AM build process, reducing overall assembly complexity.
2Ease of manufacture
If multiple materials are joined during AM build process, then integrated manufacturing is achieved, but interlayer bonding strength and material compatibility issues arise
Solution Approach 1:
The patent introduces specialized joiner structures as intermediary elements between different materials and layers. These joiners are designed with specific geometries and material properties that facilitate strong bonding between incompatible materials, acting as mediators that bridge material compatibility gaps.
Solution Approach 2:
The patent employs composite joiner structures combining different materials with complementary properties. The joiners themselves may be composite structures that provide both mechanical strength and chemical compatibility between dissimilar base materials, enabling integrated manufacturing of multi-material parts.
3Ease of manufacture
If multiple materials are joined during AM build process, then integrated manufacturing is achieved, but material compatibility and adhesion between different materials deteriorates
Solution Approach 1:
The patent introduces specialized joiner structures as intermediary elements between different materials and layers. These joiners are designed with specific geometries and material properties that facilitate strong bonding between incompatible materials, acting as mediators that bridge material compatibility gaps.
Solution Approach 2:
The patent performs preliminary preparation of joiner interfaces during the AM build process itself. Receptacles are pre-formed in one material before the second material is deposited, ensuring proper positioning and surface preparation for subsequent joining operations, thereby improving material compatibility.
4Strength
If conventional joining methods are used, then material fastening is achieved, but manufacturing time and process complexity increase
Solution Approach 1:
The patent merges the joining operation with the base manufacturing process. Joiners are bulk-deposited as part of the normal AM build sequence rather than being added as separate post-processing steps, eliminating additional manufacturing time while achieving strong material fastening.
Solution Approach 2:
The patent maintains continuous material deposition and build operations without interruption for joining operations. The AM tool head continuously deposits material to form joiners and anchor structures as part of the ongoing build process, eliminating idle time associated with conventional joining methods.
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 enhances the strength and durability of 3D printed parts by creating robust interlayer and intermaterial bonds, enabling the production of complex multi-material products with improved mechanical properties and simplified assembly, while also allowing for easy separation of printed parts from the build platform.
Implementation Method 1
an anchor of a second material which anchor is bulk deposited by an additive manufacturing tool head in a receptacle in a body of a first material
Data Source
AI summary
Joiners, methods of joining, and related systems for additive manufacturing are provided. The method of joining includes bulk depositing, by an additive manufacturing tool head, a joiner (anchor) of a second material in a receptacle in a body of a first material. Also, the method of joining includes depositing an anchor layer of a third material upon the anchor. Networks of joiners in 3D printed parts, multi-material parts comprising joiners, computer program products for providing joiners, joiner systems including trolleys, and related methods and systems are also provided. Further provided is a system, and method, for securing a part to a build platform and separating the part from the build platform.