Monolithic Dashboard via FDM Layering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing motor-vehicle dashboards are inefficient in reducing time to market, accommodating variants and customizations, and minimizing investments, while ensuring necessary rigidity and incorporating functional sub-assemblies without additional assembly operations.
Innovation Solution
A method utilizing a robotic deposition system with FDM technology to create a monolithic dashboard by alternating layers of materials with structural and sound-absorbing characteristics, forming a longitudinal hollow bearing-element and casing, which integrates ventilation channels for structural reinforcement and functional sub-assemblies in a single piece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional dashboard production methods are used, then assembly operations can be performed with standard equipment, but production time is extended and customization capability is reduced
Solution Approach 1:
The patent applies parameter changes by utilizing FDM technology to deposit materials with varying characteristics (structural reinforcement vs. sound-absorbing) in alternating layers, allowing the dashboard to be customized for different vehicle types (passenger car, SUV, van) and production volumes while maintaining structural integrity and reducing production time
Solution Approach 2:
The patent employs composite materials by combining two distinct material types with different properties (structural reinforcement material and sound-absorbing material) in a layered composite structure, enabling both structural requirements and acoustic performance while facilitating rapid customization through material selection
2Adaptability or versatility
If material alternation is performed frequently within the same layer, then customization and variants are enabled, but production time increases due to material change operations
Solution Approach 1:
The patent applies segmentation by dividing the dashboard into distinct zones (first zone and second zone) that can be produced with different material configurations. This allows variants to be created by modifying only specific segments rather than the entire dashboard, reducing material change time while maintaining customization capability
Solution Approach 2:
The patent implements local quality by allowing different material compositions and layer configurations in different zones of the dashboard. Each zone can be optimized for its specific function (structural support, sound absorption, ventilation) while enabling localized customization without requiring global material changes
3Productivity
If a monolithic structure is produced with integrated functional sub-assemblies, then assembly operations are reduced, but production complexity increases
Solution Approach 1:
The patent applies merging by integrating multiple functional sub-assemblies (ventilation channels, structural reinforcements, sound-absorbing elements) directly into the monolithic dashboard structure during additive manufacturing. This eliminates post-assembly operations while the robotic system manages production complexity through automated material deposition and layer-by-layer construction
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 significantly reduces production time and investment costs, enables efficient customization, and produces a dashboard with enhanced rigidity and integrated functional elements, suitable for premium segment products with low production volume.
Implementation Method 1
setting up of a robotic deposition system for a plurality of materials with fused deposition modeling (FDM)
Implementation Method 2
a method, known in the art, in which an energy source is used, such as a laser or plasma beam, to selectively melt layers of powders or sheets of metal material or plastic material
Data Source
Figure 1
Figure 2~4
AI summary
A production method of a dashboard (1) of a motor-vehicle by means of additive manufacturing technology, wherein the following steps are envisaged: - setting up of a robotic deposition system (2) for a plurality of materials with fused deposition modeling FDM technology, - operating the robotic system (2) so as to start a step of depositing said plurality of materials to produce a first end (1A) of the dashboard (1), and to continue depositing the materials by creating a succession of different layers, alternating materials with different types of filaments, in particular, at least one material with structural characteristics (9) and at least one material with sound-absorbing characteristics (5), - continuing to operate said robotic system (2) so as to produce said dashboard (1) as a single monolithic element made of different materials, comprising a casing (3) incorporating a longitudinal hollow bearing-element (4) defining a central ventilation channel, designed to receive further channeling elements of a conditioning system and to perform a function of structural reinforcement of said dashboard (1).