AM Part Retention Features for Adhesive Curing Alignment

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Solution Overview

Problem

Additive manufacturing (AM) faces challenges in maintaining precise alignment and integrity of connections between parts during adhesive application and curing, as positive pressure from adhesives can cause separation and expansion leads to misalignment or faulty connections.

Innovation Solution

Incorporating retention elements such as snap-rings, screws, shims, spring-loaded clips, snap-like features, pins, magnets, and Christmas tree fasteners into the AM parts to secure them during adhesive application and curing, ensuring accurate positioning and preventing separation or expansion-induced misalignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If adhesive is applied between two parts, then bonding connection is achieved, but positive pressure from adhesive causes separation and misalignment of parts

Engineering Contradiction:

Improvebonding connection strengthVSAvoidparts alignment precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

Retention elements are installed before adhesive application to preemptively counteract the separating force. These elements apply preliminary clamping action that opposes the adhesive's positive pressure, preventing separation and maintaining alignment throughout the bonding process.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

Retention elements serve as intermediary components between the two parts being bonded. They mediate the interaction by providing mechanical restraint during adhesive application, allowing the adhesive to bond without causing misalignment, and are subsequently removed after bonding completes.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If adhesive expands or shifts during curing, then bonding process completes, but position of adhered parts deviates from intended connection

Engineering Contradiction:

Improvebonding process completionVSAvoidconnection position accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Retention elements provide continuous clamping force during the entire adhesive curing process, counteracting expansion forces as they develop. This preliminary anti-action maintains precise positioning throughout the curing timeline, ensuring the final connection matches the intended design position.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

Parts are positioned and clamped by retention elements before adhesive curing begins. This preliminary positioning action establishes the correct geometric relationship between parts, which is then maintained throughout curing, ensuring the final bonded connection achieves the intended position accuracy.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If retention elements are added to secure parts during adhesive application, then parts alignment and separation prevention is improved, but device complexity increases

Engineering Contradiction:

Improveparts alignment and connection integrityVSAvoidassembly process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Retention elements are designed as separate, removable components that are installed temporarily during adhesive application and then removed after bonding completes. This extraction approach allows the retention function to be added only when needed, avoiding permanent complexity in the final assembled product while still providing necessary alignment control during manufacturing.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Retention elements are discarded after serving their temporary purpose of maintaining alignment during adhesive curing. They are recovered (removed) from the assembly once the adhesive bond is established, allowing the final product to achieve its intended simplicity while having benefited from the temporary retention features during manufacturing.

Inventive Principle:

Principle #34Discarding and recovering

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

These retention features allow for precise and stable bonding of AM parts, reducing the risk of misalignment and ensuring a strong, reliable connection, while being removable or integratable for added reinforcement, thus enhancing the manufacturing process and product integrity.

Implementation Method 1

magnets, and Christmas tree fasteners into the AM parts to secure them during adhesive application and curing

Methodology Applied

Scientific EffectMagnetic attraction: Magnetism

Data Source

PatentUS11806941B2Mechanical part retention features for additively manufactured structures

Publication Date: 2023.11.07 DIVERGENT TECHNOLOGIES INC

AI summary

Part retention features are disclosed for securing additively manufactured (AM) parts or for securing an AM part with another component, such as a node, panel, tube, extrusion, and the like, while an adhesive is being applied and/or while the adhesive is undergoing expansion due to a subsequent curing process. The retention features described herein can be used in the context of one or more AM parts such that the elements used to house the retention features (e.g., grooves, apertures, elastic elements, etc.) can advantageously be co-printed with the AM part, thereby removing a manufacturing step. The retention features also can be made with flatter profiles than existing solutions, making the overall structure smaller and less cumbersome to assemble.