In-situ Fixture Installation via Heat Ablation and Additive Manufacturing
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Solution Overview
Problem
Conventional methods for installing fixtures or brackets on vehicle structures, such as aircraft or spacecraft, are inefficient due to the need for pre-treatment, separate manufacturing of fixtures, and the use of mechanical fasteners or adhesives, which increase process costs and complexity.
Innovation Solution
A method involving heat ablation to pre-treat the surface, followed by in-situ formation of the fixture using additive manufacturing based on a digital model, eliminating the need for separate fixtures and allowing for direct bonding or mechanical connection to the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fasteners like rivets and screws are used to secure fixtures, then the fixture can be firmly attached to the structure, but the process requires bores, positioning operations, fastening operations, and sealing steps which increase process costs and complexity
Solution Approach 1:
The patent merges the fixture design with the structure by directly forming the fixture as an integral part of the structure through additive manufacturing. This eliminates separate fastening components and integrates the attachment function into the structure itself, thereby reducing process complexity while maintaining attachment strength.
Solution Approach 2:
The patent replaces the mechanical fastening system (rivets, screws, bores, sealing operations) with a direct formation system where the fixture is additively manufactured directly on the structure. This substitution eliminates the need for mechanical fasteners and associated complex operations.
2Strength
If adhesive attachment is used to secure fixtures, then the fixture can be attached to the structure, but both the fixture and attachment surface require pre-treatment like roughening and degreasing, and additional operations are needed which increase process costs
Solution Approach 1:
The fixture is merged with the structure through direct additive manufacturing, eliminating the need for separate adhesive application processes and associated pre-treatment operations. The fixture becomes an integral extension of the structure.
Solution Approach 2:
The patent extracts the adhesive attachment step and associated pre-treatment operations from the manufacturing process by directly forming the fixture onto the structure, thereby simplifying the manufacturing process while maintaining attachment strength.
3Ease of manufacture
If separate fixtures are manufactured and then installed on the structure, then the fixtures can be pre-fabricated and inventoried, but this requires separate manufacturing operations, inventory management, and installation steps which reduce production efficiency
Solution Approach 1:
The fixture is formed in situ directly on the structure at the time of installation, eliminating the need for preliminary separate manufacturing and inventory storage. The digital model is converted directly into the physical fixture at the installation location.
Solution Approach 2:
The system performs self-service by generating the fixture digitally and manufacturing it on-demand at the installation location, eliminating the need for external manufacturing facilities and inventory management systems.
4Extent of automation
If fixtures are formed using additive manufacturing in situ, then the installation process is automated and flexible, but the surface of the structure must be pre-treated by heat ablation to ensure proper connection
Solution Approach 1:
Heat ablation is performed as a preliminary action to pre-treat the structure surface before additive manufacturing of the fixture. This ensures proper adhesion and connection between the fixture and structure while enabling automated in-situ formation.
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 enhances production efficiency by automating the installation process, reducing inventory needs, and enabling flexible design adaptations, while ensuring strong connections without the need for additional fasteners or extensive pre-treatment steps.
Implementation Method 1
pre-treating a surface region of the structure by heat ablation using the apparatus
Implementation Method 2
the ablation may effectively remove any residues of peel-plies, release films or mould release agents
Data Source
Figure 1~2(d)
Figure 3~4
Figure 5~6
AI summary
Method of installing a fixture or bracket (1) in a fuselage structure (F) of an aircraft (A) or spacecraft (T). The method comprises the steps of: arranging an apparatus (100) in, on or adjacent the structure (F); pretreating a surface region (Z) of the structure (F) by heat ablation using the apparatus (100); and forming the fixture (1) in situ on the structure (F) at the pre-treated surface region (Z) using the apparatus (100) based on a digital model (M) of the fixture (1), wherein the fixture (1) is installed by connecting the fixture (1) to the structure (F) at the pre-treated surface region (Z) as the fixture (1) is formed. Apparatus (100) for installing a fixture (1), such as a bracket, in or on a structure (F) of an aircraft or spacecraft, the apparatus (100) comprising: an ablation device (9) for generating and directing an ablating beam (LB, PS) onto a surface region (Z) of the structure (F) to pre-treat the surface region (Z); a device (7), especially an additive manufacturing device, for forming the fixture (1) in situ on the pre-treated surface region (Z); and a controller (P) for controlling the ablation device (9) and/or of the additive manufacturing device (6) at the surface region (Z) of the structure (F).