Hybrid Component Reinforcement With Deformation Compensation
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Solution Overview
Problem
Conventional methods for producing components with high load-bearing capabilities often result in uniform wall thickness, which can be inefficient and costly, as they do not allow for targeted reinforcement of specific stress points, and may require complex post-processing to correct deformations caused by additive manufacturing.
Innovation Solution
A method that involves providing a base structure with a predefined wall thickness and applying supplemental structures through additive manufacturing, where the deformation during the process is intentionally managed to achieve a target shape, eliminating the need for post-processing and allowing for precise reinforcement and compensation of stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additive manufacturing is used to apply supplemental structures to a base structure, then targeted reinforcement of stress points is achieved, but deformations occur that require complex post-processing
Solution Approach 1:
The base structure is pre-deformed before additive manufacturing to compensate for the deformations that will occur during the process. This preliminary action ensures that after the additive manufacturing process completes and the supplemental structures are applied, the component achieves the desired target shape without requiring complex post-processing operations.
Solution Approach 2:
A counteracting deformation is intentionally applied to the base structure before additive manufacturing to offset the harmful deformations that will occur during material deposition. This preliminary anti-action neutralizes the negative effects of thermal stresses and phase transformations, allowing the component to maintain its target shape after processing.
2Strength
If uniform wall thickness is used in conventional manufacturing, then high load-bearing capability is ensured, but material usage and weight increase
Solution Approach 1:
The component is designed with variable wall thickness where different regions have different thicknesses based on their specific load requirements. Critical stress points and high-load areas have increased wall thickness for strength, while low-stress areas have reduced wall thickness to minimize material usage and weight. This local differentiation optimizes the strength-to-weight ratio of the component.
Solution Approach 2:
The component is divided into multiple regions with different wall thickness characteristics. The base structure provides the primary load-bearing framework with minimum required thickness, while supplemental structures are selectively added to specific segments that require additional reinforcement. This segmentation allows precise material placement only where needed.
3Strength
If wall thickness is increased at the position of highest load, then the component can withstand high loads, but the entire component requires increased wall thickness
Solution Approach 1:
Instead of uniformly increasing wall thickness throughout the entire component, the solution applies increased thickness only to the specific location experiencing the highest loads. The base structure maintains minimum required wall thickness in low-stress areas, while supplemental structures add material only where structurally necessary to withstand high loads, thereby optimizing material usage.
Solution Approach 2:
The base structure is designed with minimum sufficient wall thickness that provides partial load-bearing capability. Supplemental structures then provide the additional material needed specifically at critical locations to achieve the required strength, rather than over-designing the entire component with excessive material throughout.
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 and cost-effectively produces components with optimized wall thickness and stress distribution, reducing material usage and weight while ensuring the component achieves the desired final shape without additional deformation, making it suitable for various technical devices.
Implementation Method 1
an additive manufacturing process in which material is applied to the base structure in a melting and solidification process and is thereby integrally bonded to the base structure
Implementation Method 2
an additive manufacturing process in which material is applied to the base structure in a melting and solidification process and is thereby integrally bonded to the base structure
Implementation Method 3
deformations in the material can occur due to the additive manufacturing process (particularly in processes in which a heat input into the base structure takes place)
Data Source
AI summary
A method of producing a component for a technical device which has a base structure and one or more supplemental structures. The base structure is not additively manufactured, the one or more supplemental structures is/are applied onto the base structure by means of an additive manufacturing process, and the base structure is subjected to a deformation during the additive manufacturing process. The base structure is provided with a starting shape which is selected such that the deformation leads to a desired target shape of the base structure. The invention likewise relates to a corresponding component.