Modular 3D-Printed Transport Frames Beyond AM Build Size Limits
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Solution Overview
Problem
The use of additive manufacturing (AM) in transport structures has been limited to producing small-scale components, with untapped potential for larger and more sophisticated substructures due to constraints in build size, precision, and integration with existing manufacturing processes.
Innovation Solution
The application of AM techniques such as Direct Metal Deposition (DMD) and Powder Bed Fusion (PBF) to print entire frames and bodies of transport structures, combined with modular design and multi-aspect printing, allowing for the integration of various components and efficient recycling of materials, enabling the production of complex and customizable transport structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing is used to produce transport structure components, then design flexibility and customization are improved, but build size limitations prevent production of large-scale structures
Solution Approach 1:
The transport structure is divided into multiple modular components that can be additively manufactured separately within build size constraints, then assembled into a complete large-scale structure. This segmentation allows each component to be produced within the limitations of current AM technology while the overall structure achieves the desired large scale and design flexibility.
2Shape
If additive manufacturing is used for transport structures, then production of complex geometries is improved, but manufacturing precision and integration with existing processes deteriorate
Solution Approach 1:
Complex transport structures are segmented into multiple components that can be manufactured with higher precision using AM. Each segmented component maintains geometric complexity while reducing overall dimensional tolerance accumulation, thereby improving manufacturing precision while preserving design freedom.
Solution Approach 2:
Additive manufacturing processes are integrated with existing manufacturing workflows by combining AM-produced complex components with traditionally manufactured parts. This hybrid approach allows complex geometries to be produced where AM provides advantage while maintaining precision requirements through established processes for critical components.
3Loss of substance
If entire frames and bodies are printed using AM, then material recycling efficiency is improved, but production time and process complexity increase
Solution Approach 1:
Rather than printing entire frames and bodies as single monolithic components, the structure is segmented into multiple smaller components that can be manufactured in parallel. This reduces build time for each component while maintaining high material utilization rates, and enables more efficient powder recycling through smaller, manageable build volumes.
Solution Approach 2:
Instead of additively manufacturing every component of a transport structure, AM is applied selectively to specific components where geometric complexity provides the greatest value. This partial application reduces overall production time and process complexity while still achieving significant material recycling benefits in the AM-produced portions.
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 creation of larger, complex transport structures with enhanced safety features, improved repairability, and reduced production costs, while allowing for customization and efficient recycling, thereby maximizing production efficiency and flexibility.
Implementation Method 1
DMD is an AM technology that uses a laser to melt metallic powder and thereby transform it into a solid metal object
Implementation Method 2
Other AM processes such as powder bed fusion (PBF) use a laser to sinter or melt powdered material, which then bonds the powder particles together in targeted areas to produce a 3-D structure having the desired geometry
Data Source
AI summary
Some embodiments of the present disclosure relate to an additively manufactured transport structure. The transport structure includes cavities into which components that use an external interface are inserted. A plurality of components are assembled and integrated into the vehicle. In an embodiment, the components and frame are modular, enabling reparability and replacement of single parts in the event of isolated failures.