Load-Path Mounting Bracket Forming for Lightweight Mass Production
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Solution Overview
Problem
Existing manufacturing methods struggle to produce complex, load-bearing articles with reduced material usage while ensuring consistent quality and cost-effectiveness, particularly in additive manufacturing processes like 3D printing.
Innovation Solution
A method for manufacturing mounting brackets with a load-path approximated lower-mass structure, formed from a planar body through bending and shaping operations, utilizing topology optimization and generative design to create a non-planar structure with less material in non-load-bearing regions, suitable for mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If additive manufacturing (3D printing) is used to manufacture complex iterative designs, then complex shapes with reduced material usage can be produced, but production cost increases and quality assurance becomes difficult
Solution Approach 1:
The patent uses a planar body as a template or copy that can be repeatedly formed into identical three-dimensional articles. This allows mass production of complex shapes through forming operations on standardized planar blanks, ensuring consistent quality while reducing material usage compared to traditional manufacturing of solid articles.
Solution Approach 2:
The patent changes the physical state and form of the planar body through forming operations (bending, shaping) to create three-dimensional articles with complex geometries. This transformation allows achievement of additive manufacturing's design flexibility while using conventional forming processes that offer better quality control and lower cost.
2Productivity
If conventional manufacturing methods are used to produce articles, then mass production at lower cost is achieved, but complex shapes and reduced material usage cannot be attained
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: first, creating a standardized planar body with the optimized material distribution pattern; second, forming the three-dimensional article through bending and shaping operations. This segmentation allows the complex shape to be achieved through forming rather than direct manufacturing, enabling both mass production and geometric complexity.
Solution Approach 2:
The patent transitions from two-dimensional planar bodies to three-dimensional articles through forming operations. The planar body serves as a developmental stage that, when formed, creates the final three-dimensional shape with complex geometry. This dimensional transformation enables conventional manufacturing to produce shapes previously only achievable through additive manufacturing.
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
The method enables the production of lightweight, load-bearing brackets with complex shapes at lower costs and improved quality assurance, reducing material waste and production costs compared to conventional methods.
Implementation Method 1
carrying out a forming operation on the planar body to form a non-planar structure
Data Source
AI summary
A mounting bracket (50) comprises a non-planar structure shaped by bending one or more portions of a planar body, wherein the planar body comprises before it is formed into a planar body a two-dimensionally profiled load-path approximated lower-mass structure. The planar body may be a blank stamped from material sheet or a slice separated from a profiled material block. The two-dimensionally profiled planar body may be iteratively designed using load-path analysis taking account of functional regions and preserve regions. The bracket may be used as load support for wall and roof cladding installations that require a large number of support brackets.