Integrated Conductor Tracks in Additive Manufacturing
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Solution Overview
Problem
Current additive manufacturing processes for creating conductor tracks within metal components face challenges such as limited suitable insulating materials, difficulty in processing, and resulting components with cracks and pores, as well as inflexibility and complexity in integrating electronics or cables.
Innovation Solution
A method using a powder-based additive manufacturing process to integrate conductor tracks within components layer by layer, with the conductor track being built simultaneously with the component, allowing for a single-piece manufacturing without reducing quality, and incorporating features like protrusions for heat dissipation and electrical contact, along with optional insulation and support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If metal-based additive manufacturing processes (laser beam melting, binder jetting, cold gas spraying) are used to print conductor tracks into metal components, then conductor tracks can be integrated into metal components, but the processing is very difficult and the component properties are riddled with cracks and pores
Solution Approach 1:
The patent merges the manufacturing of the metal component and the conductor track into a single integrated process. The conductor track is manufactured simultaneously with the component using the same powder bed additive manufacturing process, eliminating the need for separate post-processing steps that cause damage. The digital model integrates both the component geometry and conductor track routing, and the laser selectively melts powder to create both structures in one build process.
Solution Approach 2:
The conductor track is prepared and manufactured in advance together with the component during the additive manufacturing process, before the component undergoes any post-processing. The digital overall model positions the conductor track within the component model beforehand, and the laser beam creates both structures simultaneously during the build process, preventing subsequent damage from post-processing operations.
2Adaptability or versatility
If insulating materials are processed using metal-based additive manufacturing processes to enable conductor track printing, then conductor tracks can be printed, but the processing is very difficult to implement and component properties deteriorate
Solution Approach 1:
The patent changes the fundamental parameter of the manufacturing process from metal-based to plastic-based additive manufacturing. This parameter change enables the use of plastic insulating materials that are compatible with the extrusion-based printing process. The conductor track is printed using conductive adhesive or conductive material within the plastic-based process, eliminating the difficulties associated with processing insulating materials in metal-based processes.
3Adaptability or versatility
If electronics or cables are inserted in the additive manufacturing process, then conductor tracks can be integrated, but the process becomes inflexible and complex to implement
Solution Approach 1:
The patent extracts the conductor track from the category of separate components (electronics or cables) and integrates it directly into the component structure through the additive manufacturing process. The conductor track is printed as an integral part of the component using the same manufacturing process, eliminating the need for separate insertion operations and reducing overall system complexity.
Solution Approach 2:
The additive manufacturing process is made multi-functional by enabling it to create both the component structure and the conductor track simultaneously. The same extrusion-based process that creates the plastic component also deposits conductive material to form the conductor track, eliminating the need for separate electronics insertion processes and reducing overall process complexity.
4Adaptability or versatility
If conductor tracks are printed into plastic-based components using conductive adhesives, then conductor tracks can be integrated, but the manufacturing quality and structural integrity are reduced
Solution Approach 1:
The patent merges the structural component manufacturing and conductor track creation into a single integrated process. Both the plastic component and the conductor track are manufactured simultaneously using the same extrusion-based additive manufacturing process, ensuring that the conductor track becomes an integral part of the component structure rather than a separate adhesive layer, thereby maintaining structural integrity.
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
Enables high-quality components with integrated conductor tracks and sensors/actuators, free from cracks and pores, with improved thermal management and electrical insulation, while maintaining manufacturing quality and flexibility.
Implementation Method 1
A widespread method is metal-processing laser beam melting
Implementation Method 2
joint manufacturing of the component and the conductor track running within the component using the powder-based, additive manufacturing process
Data Source
Figure 1
Figure 2a~2d
Figure 2e~2gii
AI summary
The present invention relates to a method for manufacturing a component with a conductor track extending at least partially within the component using a powder bed-based additive manufacturing process, wherein the method comprises: creating a digital model of the component and a digital model of the conductor track, creating a combined digital model, wherein the model of the conductor track is positioned within the model of the component, and jointly manufacturing the component and the conductor track extending at least partially within the component using the powder bed-based additive manufacturing process.