Additive Plastic Component With Injection Molded Shell
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Solution Overview
Problem
Additive manufacturing of plastic components often results in surface properties that are undesirable for certain applications, such as being inferable haptically and visually due to layered construction, necessitating a method to produce components with desired surface properties like haptic, mechanical, and optical characteristics.
Innovation Solution
A method involving the formation of a main body structure through additive manufacturing with a defined undersize, followed by the attachment of a shell element to achieve the desired dimensions and surface properties, which can include mechanical, thermal, or functional enhancements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additive manufacturing processes are used to produce plastic components, then geometric freedom and batch production capability are improved, but surface properties become undesirable with visible and haptic layering
Solution Approach 1:
The plastic component is divided into two distinct segments: a main body structure produced by additive manufacturing and a shell element produced by injection molding. This segmentation allows each part to be optimized for its specific manufacturing process, with the shell providing the desired surface properties while the main body provides geometric freedom.
Solution Approach 2:
The invention creates a composite structure combining two different plastic materials: the main body material from additive manufacturing and the shell material from injection molding. This composite approach allows the final component to exhibit properties of both materials, including the smooth surface of the shell and the complex geometry of the main body.
2Ease of manufacture
If additive manufacturing is used for plastic components, then production flexibility is improved, but surface finish quality deteriorates with layered construction visible
Solution Approach 1:
The component is segmented into main body and shell, allowing the main body to be manufactured with additive manufacturing's production flexibility while the shell is manufactured separately with injection molding's superior surface finish capabilities.
Solution Approach 2:
Different regions of the component receive different treatment: the main body retains the additive manufactured surface characteristics, while the outer shell region receives a separately molded surface with high-quality finish properties appropriate for its functional requirements.
3Manufacturing precision
If shell elements are attached to main body structure, then desired surface properties and target dimensions are achieved, but device complexity increases
Solution Approach 1:
The shell element and main body structure are merged into a single integrated component through attachment processes such as adhesive bonding, mechanical interlocking, or ultrasonic welding. This merging achieves the desired target dimensions and surface properties while presenting a unified final product.
Solution Approach 2:
The shell element is pre-formed through injection molding with the desired surface properties and dimensional tolerances before being attached to the main body. This preliminary action allows precise control of the final dimensions without requiring complex post-processing of the additive manufactured component.
Data Source
AI summary
The invention relates to a method for producing a plastic component (1) having defined target dimensions, in particular defined target outer dimensions, said method comprising: —forming a one- or multi-part base body structure (2) in an additive manufacturing process, wherein the base body structure (2) is formed with an undersize with respect to the defined geometric target dimensions, —attaching at least one enveloping element (3) enveloping the base body structure (2) on the exposed surfaces of the base body structure (2) by forming the plastic component (1) that is to be produced, wherein an enveloping element (3) is used, the wall thickness of which compensates the undersize of the base body structure (2) with respect to the defined geometric target dimensions of the plastic component (1).