3D-Printed Component Interlock With Deformable Protuberances
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Solution Overview
Problem
Additive manufacturing (3D printing) often results in gaps between interlocked components due to lower dimensional and shape accuracy compared to traditional subtractive machining, leading to suboptimal coupling, and existing solutions like welding or additional machining introduce drawbacks such as non-separability or increased waste and production costs.
Innovation Solution
A method using a dovetail interlock with protuberances on one or both components, where the protuberances deform to ensure zero-gap contact, allowing components made by additive manufacturing to interlock without gaps, while avoiding additional processing like welding and ensuring repeatable manufacturing across different machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additive manufacturing is used to manufacture components, then production costs and times are reduced and complex shapes are achieved, but dimensional accuracy decreases causing gaps between interlocked components
Solution Approach 1:
The patent applies preliminary action by designing protuberances with predetermined deformation characteristics into the additive manufactured component. These protuberances are pre-engineered to deform during assembly, compensating for dimensional inaccuracies before the interlocking occurs. This allows the component to self-correct gaps without requiring post-manufacturing adjustments or additional processing steps.
Solution Approach 2:
The patent utilizes parameter changes by modifying the geometric parameters of the protuberances (size, shape, material properties) to control their deformation behavior. By adjusting these parameters, the protuberances can deform to specific extents to eliminate gaps caused by additive manufacturing tolerances, while maintaining the overall benefits of additive manufacturing for complex geometries and cost reduction.
2Manufacturing precision
If welding points are applied to avoid gaps, then coupling between components is improved, but additional processing is added and disassembly is prevented
Solution Approach 1:
The patent applies self-service by designing the protuberances to automatically deform and fill gaps during the normal assembly process. The component itself performs the gap-filling function through the elastic or plastic deformation of its own protuberances, eliminating the need for external welding operations or additional processing steps. This maintains simplicity while achieving zero-gap coupling.
3Manufacturing precision
If subtractive machining is performed on additive manufactured components, then dimensional accuracy is improved, but material waste increases and production costs rise
Solution Approach 1:
The patent applies preliminary action by incorporating gap-compensating protuberances directly into the additive manufacturing process. This eliminates the need for subsequent subtractive machining operations that would remove material to achieve dimensional accuracy. The protuberances are pre-designed to deform and create zero-gap coupling, preserving both the material and the cost benefits of additive manufacturing.
4Manufacturing precision
If dimensional parameters are varied through multiple manufacturing runs, then coupling accuracy is improved, but production costs and setup times increase
Solution Approach 1:
The patent applies parameter changes by modifying the protuberance geometry parameters (size, shape, material properties) to compensate for additive manufacturing tolerances. This approach achieves zero-gap coupling through a single manufacturing run with fixed parameters, eliminating the need for multiple iterative manufacturing runs and parameter adjustments. The protuberance design inherently accounts for dimensional variations, making the process repeatable and cost-effective.
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 method achieves zero-gap interlocking, reduces processing waste and production costs, and ensures reliable, repeatable assembly without the need for additional machining or welding, maintaining the benefits of additive manufacturing while enhancing coupling accuracy.
Implementation Method 1
the protuberances are sized to exhibit elastic or plastic deformation to ensure zero-gap interlocking
Implementation Method 2
the protuberances are sized to exhibit elastic or plastic deformation to ensure zero-gap interlocking
Data Source
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AI summary
A method to interlock two components (3, 4) of an automatic machine for manufacturing or packing consumer articles. The method comprises the steps of: manufacturing a first component (3) with a recess (6); manufacturing a second component (4) with a projection (7) reproducing the shape of the recess (6) through additive manufacturing; and joining the two components (3, 4) by inserting and locking the projection (7) of the second component (4) in the recess (6) of the first component (3). The projection (7) has a plurality of protuberances (11) configured to interfere with the recess (6), and the insertion of the projection (7) of the second component (4) into the recess (6) of the first component (3) causes the progressive deformation of all the protuberances (11).