Composite Body Assembly via Solvent Bonding of 3D-Printed Parts
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Solution Overview
Problem
Existing additive manufacturing processes face challenges in producing large bodies due to limited printing device volumes, requiring complex and time-consuming assembly of smaller sub-bodies with intricate structures, and often necessitate additional smoothing and joining steps.
Innovation Solution
A method where sub-bodies produced via additive manufacturing are exposed to a solvent atmosphere in a chamber, allowing them to form a metallurgical bond and smooth surfaces while touching at joining surfaces, eliminating the need for separate assembly and smoothing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing processes are used to produce large bodies, then production simplicity and speed are improved, but the limited volume of printing devices prevents production of large bodies
Solution Approach 1:
The patent divides a large body into multiple smaller sub-bodies that can be individually produced by additive manufacturing devices with limited build volumes. These sub-bodies are then joined together to form the complete large-scale structure, enabling production of objects exceeding single-device capacity while maintaining the efficiency of additive manufacturing.
2Volume of moving object
If sub-bodies are divided for additive manufacturing, then production of large bodies is enabled, but assembly complexity and time increase
Solution Approach 1:
The patent combines multiple operations into a single integrated process: sub-bodies are positioned in a chamber, exposed to solvent atmosphere for simultaneous surface smoothing and joining, and bonded together in one step. This merges smoothing and assembly operations that would traditionally be separate, reducing overall process complexity and time.
Solution Approach 2:
The solvent atmosphere treatment is applied in advance to prepare joining surfaces on sub-bodies before assembly. This preliminary surface preparation creates optimal bonding conditions, ensuring that when sub-bodies are positioned together, they automatically form strong metallurgical bonds without requiring additional joining operations.
3Volume of moving object
If sub-bodies are assembled separately, then large bodies can be produced, but additional joining steps are required increasing time and cost
Solution Approach 1:
The patent merges surface smoothing and joining operations into a single simultaneous process. Sub-bodies are exposed to solvent atmosphere in a chamber where they undergo surface treatment and form metallurgical bonds at joining surfaces concurrently, eliminating sequential steps and reducing total process time.
Solution Approach 2:
The solvent atmosphere enables sub-bodies to self-bond at joining surfaces through metallurgical bonding without external intervention. The chemical process automatically creates strong bonds when sub-bodies are in contact, eliminating the need for separate joining operations, adhesives, or fasteners.
4Manufacturing precision
If solvent atmosphere treatment is applied to smooth surfaces, then surface quality is improved, but additional process steps are required
Solution Approach 1:
The patent combines surface smoothing and joining functions into a single solvent atmosphere treatment step. The same chemical process that smooths surfaces also activates joining surfaces for metallurgical bonding, so one process step achieves two objectives that would traditionally require separate operations.
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 method enables the production of composite bodies with improved homogeneity and cohesion, eliminating the need for additional assembly and smoothing, and allows for larger structures to be manufactured without complex post-processing.
Implementation Method 1
The solvent atmosphere at least partially breaks chemical bonds on the surface of the component parts. This allows the molecules on the surface to rearrange or be removed, thereby reducing surface roughness.
Implementation Method 2
a metallurgical bond is formed between the at least two sub-bodies at the at least one joining surface by means of the solvent atmosphere
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to a method for producing a composite body (2) from at least two sub-bodies (1), wherein at least one of the sub-bodies (1) is produced by an additive manufacturing process, and wherein the at least two sub-bodies (1) are exposed in a chamber (6) to a solvent atmosphere (7) so that a surface of the sub-bodies (1) is smoothed. The invention also relates to a composite body (2) produced according to the method. For the method, it is proposed that the at least two sub-bodies (1) are positioned in the chamber (6) such that they touch at at least one joining surface (5), and thus a metallurgical bond is formed between the at least two sub-bodies (1) at the at least one joining surface (5) by the solvent atmosphere (7).