Co-Printed Node Interconnects for Welding-Free Component Joining
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Solution Overview
Problem
Conventional manufacturing techniques, such as welding, are inefficient and costly for joining additively manufactured parts to conventional commercial components, as they may not be viable alternatives for new materials used in 3D printing, limiting the flexibility and cost-effectiveness of complex mechanical assemblies.
Innovation Solution
The technique of co-printing additively manufactured nodes and interconnects using additive manufacturing processes, which allows for the creation of complex geometries and structures, enabling the use of adhesive ports and vacuum ports to securely connect nodes to components like tubes through injection and deformation processes, reducing the need for traditional welding methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding techniques are used to join additively manufactured parts to commercial components, then strong connections can be achieved, but the manufacturing cost increases and the process becomes time-intensive
Solution Approach 1:
The node and interconnect are co-printed as a single integrated component using additive manufacturing, eliminating the need for separate joining operations like welding. This merging of components reduces manufacturing steps, lowers costs, and maintains connection strength through the continuous material structure created during co-printing
2Strength
If conventional welding techniques are used to join additively manufactured parts to commercial components, then strong connections can be achieved, but the manufacturing cost increases
Solution Approach 1:
The node and interconnect are co-printed as a single integrated component using additive manufacturing, eliminating the need for separate joining operations like welding. This merging of components reduces manufacturing steps, lowers costs, and maintains connection strength through the continuous material structure created during co-printing
3Reliability
If traditional welding methods are used for joining parts, then reliable connections are achieved, but the process is time-intensive and material-intensive
Solution Approach 1:
The node and interconnect are co-printed as a single integrated component using additive manufacturing, eliminating the need for separate joining operations like welding. This merging of components reduces manufacturing steps, lowers costs, and maintains connection strength through the continuous material structure created during co-printing
4Ease of manufacture
If conventional manufacturing techniques are used, then joining separate parts is possible, but the process requires costly materials and multiple steps
Solution Approach 1:
The node and interconnect are co-printed as a single integrated component using additive manufacturing, eliminating the need for separate joining operations like welding. This merging of components reduces manufacturing steps, lowers costs, and maintains connection strength through the continuous material structure created during co-printing
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 simplifies the joining process, reduces costs, and enhances the flexibility of manufacturing complex mechanical structures by allowing for the creation of custom shapes and configurations that were previously unattainable, providing strong and bubble-free adhesion without the time and material intensity of traditional welding.
Implementation Method 1
Selective laser melting entails fusing (agglomerating) particles of a powder at a temperature below the melting point of the powder material. More specifically, a laser scans a powder bed and melts the powder together where structure is desired
Implementation Method 2
The interconnect may include a head configured to form a joint with a socket of the node. The node and interconnect may be co-printed, or additively manufactured together during the same printing process
Data Source
AI summary
Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node. The apparatus includes an additively manufactured interconnect co-printed with the node. The interconnect is configured to connect the node to a component.