Foldable Additive Manufacturing Components with Locking Joints
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Solution Overview
Problem
Additive manufacturing technologies face limitations in reducing manufacturing space requirements and production efficiency, especially when producing large-sized components, due to restrictions on component size and assembly complexity, leading to increased production time and costs.
Innovation Solution
The method involves designing large-sized objects with at least one rotation shaft and irreversible engaging structures, allowing components to be folded during production to meet minimum distance requirements, and then unfolded post-manufacturing to maximize size, eliminating the need for additional assembly and reducing manufacturing space needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If large-sized components are manufactured through one-time manufacturing process in larger-sized molding chamber, then the component size is increased, but the production time is extended and production capacity is reduced
Solution Approach 1:
The large-sized component is divided into multiple divided components that can be manufactured separately in smaller chambers simultaneously. These divided components are then assembled together to form the complete large-sized component, thereby reducing production time while achieving the required component size.
Solution Approach 2:
The component is designed with foldable structures that allow it to occupy reduced space during manufacturing (folded state) and expand to full size after manufacturing (unfolded state). This dimensional transformation enables manufacturing in smaller chambers without compromising the final component size.
2Volume of stationary object
If components are divided to reduce size for manufacturing, then the manufacturing space is reduced, but the assembly complexity is increased
Solution Approach 1:
Multiple divided components are integrated into a single integrated component through the additive manufacturing process, which builds the complete structure layer by layer. This merging approach reduces assembly complexity compared to traditional manufacturing while still enabling manufacturing in reduced space through the foldable design.
Solution Approach 2:
The component incorporates foldable structures that transform between compact folded configurations during manufacturing and expanded unfolded configurations during use. This dimensional change allows the component to fit within smaller manufacturing chambers while maintaining full functionality and size after manufacturing.
3Reliability
If a large number of components are produced in batches with minimum distance maintained, then heat dissipation is improved and defects are prevented, but the manufacturing space efficiency is reduced
Solution Approach 1:
Multiple components are combined into a single integrated component manufactured through one additive manufacturing process. This merging eliminates the need to maintain minimum distances between separate components while still ensuring proper heat dissipation and preventing defects, thereby improving manufacturing space efficiency without compromising reliability.
Data Source
AI summary
An additive manufacturing method and an object manufactured thereby are disclosed. The object includes a first component and a second component pivotally connected to each other through a rotation shaft. A first engaging element of the first component and a second engaging element of the second component spatially correspond to each other. When the object is manufactured in a manufacturing space, the first component is close to the second component, and the first engaging element and the second engaging element are disengaged with each other. After the object is manufactured, the first component is rotated relative to the second component at an adjustment angle around the rotation shaft. The first engaging element and the second engaging element are engaged with each other and locked, to form a use space of the object larger than the manufacturing space. It is beneficial to achieve the purpose of reducing the required manufacturing space.