Geometrically Modified Bellows for Support-Free 3D Printing
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Solution Overview
Problem
Conventional flexible elements, such as multi-corrugated metal bellows, have complex and cost-intensive manufacturing processes that limit geometric design freedom, restrict flexibility, and require standardized sizes, making it difficult to achieve non-coaxial ends, varying diameters, and complex curve designs.
Innovation Solution
A flexible element with a corrugated bellows design featuring a cross-sectional contour angle greater than 30° between vertices, allowing for variable and curved shapes, and the ability to be produced without support structures using additive manufacturing, enabling customizable geometry and increased flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional forming processes (hydroforming, roll forming, elastomer forming) are used to manufacture multi-wave metal bellows, then the manufacturing process is established and predictable, but the geometric design freedom is limited and the process becomes complex and costly
Solution Approach 1:
The patent changes the manufacturing method from conventional forming processes to additive manufacturing, fundamentally altering the production parameter. This enables complex geometric designs (varying cross-sections, non-coaxial ends, curved profiles) that were impossible with traditional forming methods, while maintaining manufacturing feasibility through automated layer-by-layer construction
Solution Approach 2:
The patent transitions from two-dimensional standardized bellows designs to three-dimensional customized geometries. Additive manufacturing enables variation in all spatial dimensions (length, width, height, curvature), allowing non-coaxial ends, varying diameters, and complex curve profiles that cannot be achieved with conventional forming processes
2Productivity
If standardized dimensions are used to meet economic requirements with high production volumes, then manufacturing costs are reduced, but design freedom and flexibility are restricted
Solution Approach 1:
The patent changes the production approach from high-volume standardized manufacturing to additive manufacturing, which maintains cost-effectiveness while enabling low-volume customization. Each bellows can have unique geometric parameters (cross-sectional shape, end orientations, curvature) without requiring expensive tooling changes or reconfiguration
Solution Approach 2:
The patent adopts a mindset similar to disposable objects by treating each bellows design as a unique, application-specific component. Rather than creating long-lasting standardized designs, the additive manufacturing process allows each component to be optimized for its specific function, with geometry tailored to exact requirements without concern for reusability of the manufacturing setup
3Adaptability or versatility
If non-standard geometries (varying diameters, non-coaxial ends, curved profiles) are desired, then design freedom is improved, but conventional manufacturing processes cannot achieve these shapes
Solution Approach 1:
The patent changes the manufacturing method to additive manufacturing, which can accommodate any geometric parameter variation. The layer-by-layer construction process naturally handles varying cross-sections, non-coaxial ends, and curved profiles without requiring complex tooling or multiple manufacturing steps
Solution Approach 2:
The patent utilizes the full three-dimensional capability of additive manufacturing to create geometries that vary in all spatial dimensions. Unlike conventional forming that is limited to relatively simple shapes, additive manufacturing can create complex 3D structures including varying diameters along the length, non-coaxial end orientations, and curved centerline profiles
Data Source
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AI summary
The present invention relates to a flexible element (1) comprising a hollow bellows for compensating relative movements between two components or objects. The variable contour of the flexible element (1) has an angle (αx) to the g-axis of greater than 30° between a first vertex and a second vertex in a cross-section along a g-axis. This design is particularly advantageous in the case of additive manufacturing processes, as it eliminates the need for support structures.