Interlocking Metasurfaces for Non-Permanent Additive Manufacturing Joints
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Solution Overview
Problem
Traditional joining techniques for additively manufactured parts, such as welds, adhesives, and threaded fasteners, are limited in their ability to create non-permanent, easy-to-assemble joints, especially for complex geometries like lattices, and often result in weak or vibration-prone connections.
Innovation Solution
Interlocking metasurfaces (ILMs) fabricated through additive manufacturing, which enable mechanical interlocking of architected features to form robust, non-permanent joints, allowing for a wider range of materials and shapes, and can be designed to fine-tune performance using finite element simulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional joining techniques (welds, adhesives, threaded fasteners) are used for additively manufactured parts, then joint strength may be improved, but ease of assembly deteriorates and permanence increases
Solution Approach 1:
The metasurfaces are segmented into discrete interlocking features (protrusions and recesses) that can engage with each other mechanically. This segmentation allows the joint to be assembled by simply bringing the surfaces together, eliminating the need for complex assembly operations while maintaining strong mechanical interlocking through the array of features.
Solution Approach 2:
The patent replaces traditional mechanical joining systems (welds, adhesives, threaded fasteners) with a mechanical interlocking system based on complementary metasurface features. This substitution enables easy assembly through direct mechanical engagement while maintaining joint strength through the distributed interlocking features.
2Strength
If traditional joining techniques are used, then joint strength may be improved, but versatility deteriorates for complex geometries
Solution Approach 1:
The metasurface features are designed with local quality variations, where the geometry, size, and distribution of interlocking features can be tailored to specific locations on the surface. This allows the joining system to adapt to complex geometries and varying load conditions across different regions of the joined parts.
Solution Approach 2:
The metasurface interlocking system provides universal applicability across different part geometries and materials. The same basic principle of complementary features can be applied to various complex geometries including lattices, shells, and solid structures, making it a versatile joining solution for additively manufactured parts regardless of shape or material.
3Manufacturing precision
If microfabrication techniques are used to create interlocking metasurfaces, then manufacturing precision may be improved, but material selection deteriorates
Solution Approach 1:
The patent changes the manufacturing parameter from microfabrication processes to additive manufacturing processes. This parameter change enables the use of diverse materials (polymers, metals, ceramics) while maintaining the precision needed for interlocking features through the capabilities of modern additive manufacturing technologies.
4Manufacturing precision
If custom manufacturing processes are developed for interlocking metasurfaces, then manufacturing precision may be improved, but device complexity deteriorates
Solution Approach 1:
The patent merges the creation of interlocking features directly into the additive manufacturing process itself, rather than requiring separate custom manufacturing steps. This integration eliminates complex multi-step processes while maintaining manufacturing precision through the inherent capabilities of additive manufacturing to create complex geometries in a single process.
Data Source
AI summary
Additive manufacturing (AM) can be used to fabricate a wide palette of interlocking metasurfaces (ILMs). ILMs can be architecturally tailored to achieve intentional engagement and disengagement forces, and are amenable to topological optimization. ILMs can be fabricated using nearly any AM process at different length scales according to the capabilities of the process. As a result, ILMs represent a new class of joining technology enabled by additive manufacturing that is complementary to traditional joining processes including fasteners, welds, adhesives, etc.