3D-Printed Metal-Polymer Lattice Composite for Sealed Lightweight Parts
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Solution Overview
Problem
Existing composite materials used in automotive parts, such as metal-plastic hybrids, face challenges with sealability against fluids, brittleness, and stiffness, particularly in 3D-lattice structures produced by additive manufacturing, which limits weight reduction and structural integrity.
Innovation Solution
A method involving 3D-printing a metal lattice and introducing a polymer, such as thermoplastic, into the lattice to create a compound material with improved sealability, stiffness, and ductility, where the metal content ranges between 10-80 vol.% and the lattice features holes with diameter differences of up to 20%, allowing for efficient filling and shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a 3D-lattice structure of metal is used for weight reduction, then weight decreases, but sealability against fluids deteriorates
Solution Approach 1:
A polymer material is introduced into the hollow spaces of the metal 3D-lattice structure, creating a nested composite where the polymer fills the voids of the lattice. This nesting approach maintains the lightweight lattice framework while using the polymer to provide sealing functionality against fluids.
Solution Approach 2:
The invention creates a composite material system combining metal 3D-lattice structure with polymer filling material. The metal lattice provides structural framework and weight reduction, while the polymer composite provides sealability and fluid resistance, achieving both lightweight and sealed properties simultaneously.
2Weight of moving object
If a 3D-lattice structure of metal is used for weight reduction, then weight decreases, but brittleness increases
Solution Approach 1:
The polymer material is nested within the metal lattice structure, where it acts as an internal reinforcement that prevents crack propagation and reduces brittleness. The polymer fills the hollow spaces and bonds to the metal struts, creating a tougher composite that maintains the lightweight advantage while improving ductility.
Solution Approach 2:
The metal-polymer composite combines the high strength-to-weight ratio of metal lattice with the ductility and toughness of polymer materials. This composite structure reduces overall brittleness compared to solid metal or unreinforced lattice structures.
3Weight of moving object
If a 3D-lattice structure of metal is used for weight reduction, then weight decreases, but local stiffness decreases
Solution Approach 1:
The polymer material is introduced into the hollow spaces of the lattice, providing internal support and reinforcement. This nested polymer filling increases local stiffness by preventing buckling of the thin metal struts and providing structural support within the lattice cells.
Solution Approach 2:
The metal-polymer composite structure achieves enhanced local stiffness compared to the metal lattice alone. The polymer material compensates for the reduced stiffness of the open lattice structure, creating a composite that is both lightweight and sufficiently stiff for structural applications.
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 resulting compound material achieves a 30% weight reduction and a 10% increase in stiffness compared to solid metal, while maintaining sealability and enhanced ductility, reducing the risk of local cracking and improving impact distribution.
Implementation Method 1
introducing the at least one polymer into the 3D-lattice
Data Source
AI summary
A method of producing a compound material including at least one metal and at least one polymer includes: 3D-printing a 3D lattice of the at least one metal; and introducing the at least one polymer into the 3D-lattice.