Monolithic Fuel Fitting With Integral Sealing via Additive Manufacturing
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Solution Overview
Problem
Fuel fittings for unique or low production volume applications are costly and have long lead times due to traditional machining methods, necessitating a more economical manufacturing approach.
Innovation Solution
A method using layer-by-layer additive manufacturing to create monolithic fuel fittings with integral sealing elements, including a conduit and sealing seats, allowing for faster production and better dimensional control at lower costs compared to machining from bar stock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods are used to manufacture fuel fittings, then manufacturing precision and reliability are maintained, but production time and costs increase significantly
Solution Approach 1:
The patent replaces traditional mechanical machining processes with additive manufacturing technology. The fuel fitting is constructed by depositing material layer-by-layer according to digital models, eliminating the need for subtractive machining operations. This substitution maintains dimensional precision through controlled material deposition while dramatically reducing production time and enabling complex geometries that would be difficult or impossible to machine.
Solution Approach 2:
The invention changes the fundamental manufacturing parameter from subtractive removal of material to additive deposition of material. By controlling deposition parameters such as layer thickness, deposition rate, and material properties, the process achieves required dimensional tolerances while reducing overall manufacturing time. The additive approach allows for optimized build parameters that balance precision and productivity.
2Strength
If traditional machining methods are used to manufacture fuel fittings, then structural integrity is ensured, but production costs and lead times increase
Solution Approach 1:
The patent replaces costly mechanical machining operations with additive manufacturing, reducing material waste and production costs. The additive process builds the fuel fitting by depositing material only where needed, eliminating expensive subtractive removal and reducing lead times from weeks to days or hours, thereby improving ease of manufacture while maintaining structural integrity through controlled material properties.
Solution Approach 2:
The invention utilizes composite material structures where the fuel fitting incorporates reinforcing features and optimized material distribution within the additive-manufactured structure. This allows for cost-effective production while ensuring structural integrity through strategically placed material that optimizes strength-to-weight ratio and mechanical properties.
3Productivity
If additive manufacturing is used to create fuel fittings, then production time and costs are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the fuel fitting manufacturing into discrete layers that are deposited sequentially. This layer-by-layer approach simplifies the control of complex additive manufacturing processes by breaking down the overall manufacturing task into manageable segments, enabling precise control over geometry and properties while maintaining high production speed.
Solution Approach 2:
The invention employs preliminary action through extensive digital modeling and simulation before physical manufacturing. The fuel fitting geometry, material properties, and deposition parameters are optimized in silico before actual production, reducing the complexity of real-time manufacturing control and enabling faster production with predetermined optimal parameters.
4Adaptability or versatility
If additive manufacturing is used to manufacture fuel fittings, then complex geometries are enabled, but process control difficulty increases
Solution Approach 1:
The patent implements feedback mechanisms in the additive manufacturing process by incorporating sensors and monitoring systems that track material deposition, temperature, and other critical parameters in real-time. This feedback enables automatic adjustment of process parameters to maintain quality and control complexity, allowing for the production of complex geometries with consistent precision through closed-loop control.
Solution Approach 2:
The invention uses preliminary digital twins and virtual prototypes to predict and optimize the behavior of complex geometries before manufacturing. By simulating the additive manufacturing process and material behavior in advance, the system pre-determines optimal process parameters and identifies potential control challenges, simplifying the actual manufacturing process control while enabling complex geometries.
Data Source
AI summary
A fuel fitting assembly includes a monolithic fuel fitting formed by additive manufacturing. The fitting includes a first end, a second end, a conduit extending axially through the fitting from the first end to the second end, and a first sealing element. The first end is to be connected to a fuel line. The second end is to be connected to a device requiring or providing fuel. The first sealing element includes a sealing seat circumferentially surrounding the conduit at the second end of the fitting. The fuel fitting is integrally formed as a stack of layers of material.