Hybrid Component Structure With Additive Reinforcement at High-Stress Zones
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Solution Overview
Problem
Existing methods for manufacturing components for technical devices, such as those exposed to high loads, require full additive manufacturing, resulting in high costs and material wastage due to constant wall thickness designs that do not efficiently distribute material based on load requirements.
Innovation Solution
A method that combines non-additive manufacturing for a basic structure with a minimum required wall thickness and additive manufacturing for targeted reinforcements at high-stress areas, using optimization algorithms to determine precise locations for material application, thereby reducing material usage and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If full additive manufacturing is used to manufacture components for high load conditions, then structural integrity and strength are improved, but manufacturing costs and production time increase significantly
Solution Approach 1:
The component is divided into two distinct parts: a basic structure manufactured by conventional methods and a supporting structure manufactured by additive manufacturing. This segmentation allows each part to be produced using the most appropriate method for its specific requirements, resolving the contradiction between strength and productivity.
Solution Approach 2:
Additive manufacturing is applied selectively only to regions requiring high strength and load-bearing capacity, rather than the entire component. This local application of advanced manufacturing technology maintains structural integrity where needed while improving overall manufacturing efficiency.
2Ease of manufacture
If constant wall thickness is used throughout the component, then manufacturing simplicity is improved, but material efficiency deteriorates due to over-engineering in low-stress areas
Solution Approach 1:
The wall thickness is varied locally across different regions of the component based on stress analysis. High-stress areas receive thicker walls through additive manufacturing support structures, while low-stress areas maintain minimum required thickness, eliminating material wastage without compromising strength.
Solution Approach 2:
Stress analysis and optimization calculations are performed before manufacturing to determine the precise wall thickness requirements for each region. This preliminary planning enables optimal material distribution that balances manufacturing simplicity with material efficiency.
3Loss of substance
If optimization algorithms are used to determine reinforcing locations, then material efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
Optimization algorithms and stress analysis are performed in advance during the design phase to determine optimal reinforcing locations and wall thickness distributions. This preliminary optimization simplifies the actual manufacturing process by providing clear guidelines for where additive manufacturing should be applied.
Solution Approach 2:
The component design is segmented into zones with different wall thickness requirements identified by optimization algorithms. This segmentation transforms complex optimization results into manageable manufacturing instructions, reducing overall manufacturing complexity.
Data Source
AI summary
The present invention relates to a method for producing a component manufactured in part non-additively for a technical device, wherein a basic structure of the component with a predefined wall thickness is produced by means of a non-additive manufacturing method, wherein at least one region of the component is determined with the aid of an optimisation method, wherein in the at least one region, a supporting structure is applied to the basic structure by means of an additive manufacturing method.