Disc Brake Caliper Body Modular Additive Manufacturing
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Solution Overview
Problem
Current caliper body manufacturing for disc brakes is laborious and inefficient, particularly in customizing and accessing difficult-to-reach areas for forming undercut surfaces or recesses, and fails to ensure precise geometric compliance and mechanical performance.
Innovation Solution
A caliper body comprising detachable modules produced by non-additive manufacturing techniques, connected via a junction element created through additive manufacturing, allowing for easier customization and geometric compliance, with modules processed separately before assembly to facilitate material removal and assembly into a single piece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If material removal techniques are used to customize caliper body portions, then geometric precision can be improved, but manufacturing time and labor increase significantly
Solution Approach 1:
The caliper body is divided into multiple detachable modules that can be manufactured separately using additive manufacturing. This segmentation allows each module to be produced independently without requiring laborious material removal operations, thereby maintaining geometric precision while significantly reducing manufacturing time and enabling parallel production of multiple modules.
Solution Approach 2:
The modular design allows critical geometric features to be pre-formed during additive manufacturing of individual modules, rather than requiring post-manufacturing material removal. This preliminary action embeds the geometric precision directly in the manufacturing process, eliminating the need for time-consuming finishing operations on assembled caliper bodies.
2Productivity
If additive manufacturing is used for the entire caliper body, then manufacturing speed and customization improve, but geometric precision and mechanical strength may be compromised
Solution Approach 1:
The caliper body is segmented into multiple modules manufactured by additive manufacturing, connected by precisely engineered junction elements. This segmentation allows the use of additive manufacturing for complex geometries while maintaining precision at the critical connection interfaces through specialized design of the junction elements that ensure accurate alignment and geometric compliance.
Solution Approach 2:
Different manufacturing approaches are applied to different parts of the caliper body. The detachable modules can be manufactured using additive manufacturing for speed and customization, while the junction elements connecting these modules are designed with high precision features to ensure geometric compliance. This local quality approach applies the most appropriate manufacturing method to each specific region based on its functional requirements.
3Productivity
If additive manufacturing is used for the entire caliper body, then manufacturing efficiency improves, but mechanical strength and structural integrity may be reduced
Solution Approach 1:
The caliper body is divided into multiple detachable modules connected by junction elements. This segmentation allows the use of additive manufacturing for the main body modules, improving manufacturing efficiency, while the junction elements are specifically designed and manufactured to provide strong, reliable connections that maintain overall structural integrity. The modular design allows for optimized material distribution and connection geometry.
Solution Approach 2:
The caliper body employs a composite structure combining multiple modules manufactured by additive manufacturing with specially designed junction elements. This composite approach allows the use of additive manufacturing benefits for the bulk material while incorporating high-strength connection features at critical interfaces, achieving both manufacturing efficiency and structural integrity through the synergistic combination of different manufacturing approaches.
4Strength
If traditional one-piece manufacturing is used, then structural integrity is maintained, but customization and access to critical areas become difficult
Solution Approach 1:
The caliper body is segmented into detachable modules that can be manufactured and assembled separately. This segmentation provides easy access to critical areas within the caliper body for inspection, maintenance, and customization, while the modular connection system maintains structural integrity through properly designed junction elements that ensure strong, reliable connections between modules.
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 enables faster, more efficient manufacturing with improved access to critical areas, ensuring precise geometric alignment and enhanced mechanical properties while reducing material usage and weight, thus addressing the inefficiencies and customization challenges of existing methods.
Implementation Method 1
obtained by means of an additive manufacturing technique, in particular obtained by material layering known as 3D printing
Implementation Method 2
Known additive manufacturing techniques are, for example: 3D printing, selective laser sintering and selective powder melting
Implementation Method 3
Known additive manufacturing techniques are, for example: 3D printing, selective laser sintering and selective powder melting
Data Source
AI summary
A caliper body for a disc brake is described. The caliper body is adapted to straddle an associable brake disc. The caliper body may have a first elongated portion, or a vehicle-side elongated portion, at least partially adapted to face the first braking surface. The caliper body may also have a second elongated portion, or wheel-side elongated portion, opposite to the first elongated portion and at least partially adapted to face the second braking surface. At least one part of the first elongated portion has at least a first module and at least one part of the second elongated portion has at least a second module. The first module and the second module are obtained by at least one non-additive manufacturing technique.