Additive Manufactured Collapsible Grille for Build Volume Limits
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Solution Overview
Problem
Additive manufacturing, or 3D printing, is limited by the size of the build box in powder bed fusion, requiring large products to be built in separate components and assembled, which increases time and reduces efficiency, and lacks flexibility in design customization, especially for complex items like vehicle grilles.
Innovation Solution
Products are printed in a collapsed state with interconnecting members and joints that allow relative movement and locking into an expanded state, enabling larger package sizes and efficient assembly, using additive manufacturing to create integral units that can be expanded and locked in place, such as vehicle grilles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If large products are built in separate components due to build box size limitations, then the product can be manufactured within the build box constraints, but the build time increases and manufacturing efficiency decreases
Solution Approach 1:
The grille is divided into multiple interconnecting members that can be printed separately within the build box size constraints and then assembled together to form the complete large-scale grille structure
Solution Approach 2:
Multiple interconnecting members are nested or stacked together in a collapsed state during printing to fit within the build box, then expanded to their final configuration after printing to achieve the large final product size
2Length of stationary object
If separate components are assembled after printing, then the build box size limitation is overcome, but the assembly complexity and time increase
Solution Approach 1:
The grille is segmented into multiple interconnecting members with standardized joints that simplify assembly, allowing the large product to be constructed from manageable components
Solution Approach 2:
The interconnecting members are designed with pre-formed joints and connection features that are printed as integral parts, eliminating the need for complex post-assembly operations and reducing assembly complexity
3Productivity
If traditional manufacturing methods are used for design customization, then production capacity is maintained, but flexibility and design freedom are limited
Solution Approach 1:
The additive manufacturing process allows for easy modification of design parameters and geometric features of the interconnecting members and joints, enabling design customization without sacrificing production capacity
Solution Approach 2:
The modular interconnecting member design allows different members and joint configurations to be mixed and matched, providing design flexibility and customization options while maintaining efficient manufacturing through standardized printing processes
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 allows for the efficient printing of larger products in a single build cycle, reducing build times and enhancing design flexibility, enabling the creation of complex structures that cannot be economically formed through traditional methods.
Implementation Method 1
Fusion based additive manufacturing processes create a product by depositing a layer of material, melting, and fusing the deposited material particles
Implementation Method 2
Powder bed fusion involves depositing an entire layer of powder and applying an energy source to fuse select particles together
Data Source
AI summary
Products and methods are provided for additive manufacturing of products in a collapsed state for post printing expansion in preparation for use in their intended application. A product includes interconnecting members configured for forming by printing in a collapsed state, with joints between the interconnecting members configured for relative movement of the interconnected members from the collapsed state to an expanded state. The interconnecting members define a larger package size in the expanded state than in the collapsed state. The joints are freely moveable in the collapsed state and are locked in place in the expanded state.