Monolithic 3D-Printed Clamps for Laser Target Alignment

Solution Overview

Problem

Laser projection alignment systems require precise calibration, which can be disrupted by foreign objects during the assembly of large assemblies like aircraft, leading to inefficiencies and potential damage from disassembled components.

Innovation Solution

The use of clamps with monolithic members that are coupled together via additive manufacturing, preventing separation without alteration, to securely position laser projection alignment targets and minimize foreign object damage during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional multi-component clamps are used during assembly, then ease of manufacture and assembly are improved, but foreign object damage risk and assembly inefficiency increase due to potential component separation and loss

Engineering Contradiction:

Improveease of manufactureVSAvoidforeign object damage risk

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent combines multiple clamp components into a single monolithic member formed by additive manufacturing. This merging eliminates the separation of components that could lead to foreign object damage, while the additive manufacturing process enables complex integrated geometries that would be difficult or impossible to achieve with traditional manufacturing methods.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes additive manufacturing to create a monolithic clamp member with integrated features that combine multiple functions. The additive manufacturing process allows for complex internal and external geometries, lattice structures, and integrated mounting features that would be difficult to achieve with traditional subtractive manufacturing or assembly of multiple components.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If traditional multi-component clamps are used, then ease of manufacture is improved, but productivity decreases due to time loss from disassembly and retrieval of dropped components

Engineering Contradiction:

Improveease of manufactureVSAvoidassembly efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent combines multiple clamp components into a single monolithic member formed by additive manufacturing. This merging eliminates the separation of components that could lead to foreign object damage, while the additive manufacturing process enables complex integrated geometries that would be difficult or impossible to achieve with traditional manufacturing methods.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The monolithic clamp member is designed with integrated features that prevent component loss before it can cause problems. The single-piece construction ensures that all clamp features remain attached throughout the assembly process, eliminating the need for time-consuming disassembly and retrieval operations.

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If monolithic members coupled via additive manufacturing are used, then foreign object damage risk is reduced, but device complexity increases due to integrated design

Engineering Contradiction:

Improveforeign object damage riskVSAvoiddevice complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent combines multiple clamp components into a single monolithic member formed by additive manufacturing. This merging eliminates the separation of components that could lead to foreign object damage, while the additive manufacturing process enables complex integrated geometries that would be difficult or impossible to achieve with traditional manufacturing methods.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The monolithic clamp member integrates multiple functions into a single component, including clamping features, mounting interfaces, and positioning elements. This multi-functionality reduces the number of separate parts needed while maintaining or improving the clamp's operational capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 clamps ensure precise alignment and reduce the risk of foreign object damage and assembly inefficiencies by maintaining the position of laser projection targets, facilitating successful calibration and reducing disassembly needs.

Implementation Method 1

The monolithic members of clamps according to the present disclosure may be formed utilizing an additive manufacturing method so that they are restricted from being decoupled from each other

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS8985540B1Clamps and methods of forming clamps

Publication Date: 2015.03.24 THE BOEING CO

AI summary

Apparatuses include two monolithic members that are coupled together, that are configured to move relative to each other, and that are configured so that they cannot be decoupled from each other without alteration of one or both of the two monolithic members. Methods of forming and using such apparatuses also are disclosed. Some monolithic members are formed utilizing an additive manufacturing method so that they are restricted from being decoupled from each other. Some apparatuses define clamps. Some clamps are used to precisely align laser projection alignment targets for use with laser projection alignment systems.