Co-molded Inserts via Additive Manufacturing

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Solution Overview

Problem

Current methods for manufacturing co-molded inserts for composite, plastic, and metal parts are costly, time-consuming, and prone to precision errors, requiring multiple tooling and molding operations, which restricts design complexity and increases labor costs.

Innovation Solution

The method employs additive manufacturing to create co-molded inserts with reduced tooling costs and lead time, using computer-aided design software to build inserts layer-wise, eliminating the need for fixtures and allowing for precise placement and integration of multiple parts into a single unit, utilizing materials like titanium alloys and thermoplastics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional molding and machining methods are used to create inserts, then manufacturing precision can be achieved through fixtures and jigs, but production lead time and costs increase significantly

Engineering Contradiction:

Improveinsert placement precisionVSAvoidproduction lead time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The insert is pre-formed using additive manufacturing with integrated positioning features built into its geometry during the manufacturing process itself, eliminating the need for separate fixture preparation and positioning operations that traditionally increased lead time while maintaining precision

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Traditional mechanical fixtures, jigs, and laser projection guides are replaced by geometric features inherently built into the additively manufactured insert, substituting complex mechanical positioning systems with integrated geometric constraints that achieve the same precision faster

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If multiple separately molded inserts are assembled piecemeal, then design flexibility is maintained, but labor costs and assembly time increase

Engineering Contradiction:

Improvedesign flexibilityVSAvoidassembly speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Multiple separate inserts are merged into a single integrated additively manufactured component with internal cavities and geometric features that accommodate multiple fasteners and mounting points, eliminating sequential assembly operations while maintaining the functional versatility of having multiple discrete elements

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single integrated insert component performs multiple functions simultaneously - providing structural reinforcement, mounting surfaces for multiple fasteners, and integration features for various subsystems - replacing what would traditionally require multiple separate molded inserts assembled together

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If fixtures and jigs are used for precise insert placement, then assembly accuracy improves, but equipment costs and complexity increase

Engineering Contradiction:

Improveinsert placement accuracyVSAvoidfixture and jig complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The insert is designed with self-positioning geometric features built into its structure during additive manufacturing, allowing it to locate and position itself within the mold cavity without requiring external fixtures, jigs, or alignment equipment - the part serves its own positioning function

Inventive Principle:

Principle #25Self-service

4Strength

If traditional molding operations are used for each insert, then material properties can be optimized, but the number of molding cycles and associated costs increase

Engineering Contradiction:

Improveinsert material propertiesVSAvoidnumber of molding cycles

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

Multiple molding operations for separate inserts are merged into a single co-molding operation where the integrated insert component and the main part are molded simultaneously in one cycle, reducing the number of molding operations while maintaining material property optimization through selective material placement in different regions

Inventive Principle:

Principle #5Merging (Combining)

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 reduces material usage, labor costs, and production time, enabling more complex designs with higher precision, improving mechanical performance and assembly accuracy, and enabling on-demand production of lightweight parts for various vehicles and crafts.

Implementation Method 1

providing a three-dimensional molding insert produced by a layer additive manufacturing process

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 2

co-molding the layer material and the molding insert simultaneously to produce a co-molded insert part

Methodology Applied

Scientific EffectCo-molding:

Data Source

PatentUS8383028B2Method of manufacturing co-molded inserts

Publication Date: 2013.02.26 THE BOEING CO

AI summary

A method for manufacturing a co-molded insert part for use in composite, plastic, or metal parts is disclosed. The method comprises the step of providing a three-dimensional molding insert produced by a layer additive manufacturing process. The method further comprises the step of applying a layer material in contact with at least a portion of the molding insert. The method further comprises the step of co-molding the layer material and the molding insert simultaneously to produce a co-molded insert part.