Mobile 3D Printing Assembly for Flexible Transport Structure Production
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Solution Overview
Problem
Traditional manufacturing facilities for transport structures, such as vehicles and aircraft, are inflexible and costly, limiting their ability to produce a variety of models without significant retooling and downtime, and often result in underutilization due to fixed infrastructure and high tooling costs.
Innovation Solution
A modular robotic assembly system that incorporates 3-D printing and automated constructors, allowing for flexible and automated assembly of transport structures by enabling on-site printing and reconfiguration of robotic stations, using machine-learning to optimize processes and adapt to changing demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fixed robotic assembly systems are used to achieve efficient production at volume, then productivity is improved, but adaptability deteriorates due to inflexible factory infrastructure and high retooling costs
Solution Approach 1:
The patent applies dynamics by replacing fixed robotic assembly systems with mobile robotic constructors that can move and reposition dynamically. The robotic constructors are not permanently installed but can be relocated to different assembly locations, enabling the manufacturing system to adapt to different production needs without permanent infrastructure changes.
Solution Approach 2:
The patent implements universality through robotic constructors that can perform multiple functions - they can assemble different vehicle models, print various components, and operate at different locations within the facility. This multi-functionality eliminates the need for dedicated assembly lines for each vehicle model, thereby improving both productivity and adaptability.
2Manufacturing precision
If fixed factory infrastructure is configured to produce specific models, then manufacturing precision is improved, but ease of manufacture deteriorates due to high tooling amortization costs and retooling requirements
Solution Approach 1:
The patent applies copying through on-site 3-D printing capabilities integrated into the robotic constructors. Instead of requiring expensive physical tooling and molds for each vehicle model, the system can digitally copy and print required components on-demand. This eliminates tooling amortization costs while maintaining manufacturing precision through digital design fidelity.
Solution Approach 2:
The patent implements parameter changes by using programmable robotic constructors that can change their operational parameters (assembly instructions, component specifications, printing parameters) through software updates rather than physical retooling. This allows the system to adapt to different vehicle models by changing control parameters rather than physical infrastructure, reducing retooling costs while maintaining precision.
3Manufacturing precision
If additive manufacturing is conducted at a dedicated location away from the assembly line, then manufacturing precision is improved, but adaptability deteriorates due to lack of flexibility to modify AM capabilities
Solution Approach 1:
The patent applies merging by integrating the 3-D printing capability directly into the robotic constructors at the assembly locations. Instead of having separate additive manufacturing facilities, the printing function is merged with the assembly robots, allowing components to be printed on-site and immediately assembled. This integration maintains printing quality while dramatically improving adaptability to changing production demands.
Solution Approach 2:
The patent uses the robotic constructor as an intermediary between the 3-D printing process and the assembly process. The robotic constructor performs both printing and assembly functions, acting as a mediator that connects material deposition with component installation. This intermediary role enables seamless integration of additive manufacturing into the assembly line while maintaining both print quality and operational flexibility.
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 enables the efficient and flexible production of multiple vehicle models without the need for extensive retooling, reducing costs and downtime, and allows for real-time adaptation to changing market demands, enhancing manufacturing efficiency and economic viability.
Implementation Method 1
a first one of the automated constructors includes a three-dimensional (3-D) printer to print at least a portion of a component
Data Source
AI summary
Techniques for flexible, on-site additive manufacturing of components or portions thereof for transport structures are disclosed. An automated assembly system for a transport structure may include a plurality of automated constructors to assemble the transport structure. In one aspect, the assembly system may span the full vertically integrated production process, from powder production to recycling. At least some of the automated constructors are able to move in an automated fashion between the station under the guidance of a control system. A first of the automated constructors may include a 3-D printer to print at least a portion of a component and to transfer the component to a second one of the automated constructors for installation during the assembly of the transport structure. The automated constructors may also be adapted to perform a variety of different tasks utilizing sensors for enabling machine-learning.