Nozzle Tool Assembly Using Hybrid Additive Sintering

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Solution Overview

Problem

Existing methods for manufacturing nozzle tools for sealing sheet metal folds are costly, time-consuming, and result in inadequate quality due to complex geometries and the need for expensive additive manufacturing with significant support material, leading to high replacement demands.

Innovation Solution

A method involving two-stage additive manufacturing using laser beam melting for a thin-walled first component and binder jetting for a thick-walled second component, followed by sintering to create a robust mechanical connection, eliminating the need for support structures and reducing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If additive manufacturing with support material is used to manufacture nozzle tools with complex geometries, then the manufacturing capability is improved, but the cost and time expenditure increase significantly

Engineering Contradiction:

Improvemanufacturing capabilityVSAvoidtime expenditure

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The nozzle tool is divided into multiple components (nozzle body, handle, insert) that can be manufactured separately using different additive manufacturing processes optimized for each part's geometry, then assembled together. This eliminates the need for extensive support material while maintaining complex geometries where needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different additive manufacturing parameters and processes are applied to different components based on their specific geometric requirements. For example, metal powder bed fusion is used for the thin-walled nozzle body requiring high precision, while binder jetting with ceramic green sand is used for the handle allowing complex internal channels without support structures.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If additive manufacturing with support material is used to manufacture nozzle tools with complex geometries, then the manufacturing capability is improved, but the costs increase significantly

Engineering Contradiction:

Improvemanufacturing capabilityVSAvoidmaterial cost

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The nozzle tool is divided into multiple components that can be manufactured separately using different additive manufacturing processes optimized for each part's geometry, then assembled together. This eliminates the need for extensive support material while maintaining complex geometries where needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If manual tools are used to create and maintain gap for nozzle tool, then the gap can be maintained, but errors in relative positioning and tool wear occur leading to high replacement demand

Engineering Contradiction:

Improvegap maintenanceVSAvoidpositioning accuracy

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The gap-maintaining function is merged into the nozzle tool assembly itself through integrated mechanical elements such as positioning fingers, alignment features, and flexible mounting mechanisms that automatically maintain the required gap between the nozzle and the body panel during operation, eliminating separate manual adjustment tools.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The nozzle tool incorporates dynamic elements such as flexible mounting mechanisms and adjustable positioning features that automatically adapt to variations in the body panel position and maintain consistent gap distances during the sealing process, compensating for positioning errors without manual intervention.

Inventive Principle:

Principle #15Dynamics

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 cost-effective production of nozzle tools with improved quality and precision, allowing for efficient sealing of sheet metal folds with reduced material waste and tool replacement.

Implementation Method 1

the first component is manufactured in a first additive manufacturing process, in particular by laser beam melting

Methodology Applied

Scientific EffectLaser beam melting: Laser

Implementation Method 2

a green part of the second component is manufactured in a second additive manufacturing process, in particular by binder jetting

Methodology Applied

Scientific EffectBinder jetting:

Implementation Method 3

the green part is sintered by the heat input and the mechanical connection between the first component and the produced second component is strengthened by sintering

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentEP4659878A1Method for producing a structural unit and method for coating and/or sealing a body unit at least in sections

Publication Date: 2025.12.10 VOLKSWAGEN AG

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AI summary

The invention relates to a method for manufacturing a component assembly and a method for at least partially coating and/or sealing a body assembly with the component assembly. In the method for manufacturing a component assembly (1), comprising a first component (2) and a second component (3), the first component (2) is manufactured in a first additive manufacturing process, and a green part (4) of the second component (3) is manufactured in a second additive manufacturing process. The first component (2) and the green part (4) are mechanically joined together and then heated together, whereby the green part (4) is sintered by the heat input, and the mechanical connection (10) between the first component (2) and the produced second component (3) is strengthened by sintering.