Reinforced 3D-Printed Part Joints Using Inserted Slender Connectors
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Solution Overview
Problem
Additive manufacturing (3D-printing) faces challenges such as slow production speed, quality issues like delamination, and size limitations, which hinder the efficient connection and strengthening of manufactured articles.
Innovation Solution
The use of strong and flexible slender pieces made of carbon fiber or other structural materials, combined with securing elements, to insert into pre-manufactured parts and connect them, thereby reinforcing and strengthening the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive bonding is used to join AM produced parts, then relatively strong and permanent attachments are achieved, but the method does not work well for incompatible materials
Solution Approach 1:
The patent introduces a bonding agent as an intermediary substance that facilitates the connection between dissimilar materials. The bonding agent is specifically selected to be compatible with both materials being joined, acting as a mediator that enables adhesion where direct bonding would fail. This resolves the contradiction by allowing strong bonds between incompatible materials through the intermediary bonding agent.
2Ease of manufacture
If mechanical joints are used to connect AM produced parts, then the connection method is simple and universally applicable, but the mechanical joints tend to be the weakest portion of the assembly
Solution Approach 1:
The patent combines mechanical joints with adhesive bonding to create a hybrid connection system. The mechanical joint provides structural alignment and initial strength, while the adhesive bonding reinforces the connection and distributes stresses more evenly. This merging of two connection methods eliminates the weakness of pure mechanical joints while maintaining ease of manufacture.
3Length of stationary object
If parts are manufactured in segments due to size limitations, then large objects can be created beyond printer capacity, but joining the sections strongly and effectively becomes difficult and costly
Solution Approach 1:
The patent incorporates bonding agents and mechanical joint features directly into the 3D printing process itself, rather than adding them as separate post-processing steps. During the printing of segmented parts, bonding channels, recesses, and joint features are pre-formed within the part geometry. This preliminary integration of joining features into the manufacturing process dramatically simplifies the subsequent assembly and joining operations.
4Strength
If traditional welding processes are used to join AM produced parts, then the materials can be melted and fused together, but the process is difficult and messy to operate and requires sufficient accessible surface
Solution Approach 1:
The patent replaces thermal welding processes with mechanical joining methods combined with adhesive bonding. Instead of melting and fusing materials through heat, the invention uses mechanically inserted joints reinforced with bonding agents. This substitution eliminates the mess and operational difficulty of welding while achieving comparable or superior joint strength, and works in locations where welding access is limited.
Data Source
AI summary
The present invention provides a novel and effective solution for connecting, reinforcing, sensing, and/or actuating pre-manufactured parts (such as 3D-printed parts), and also, optionally add multi-functionalities to the system; the multi-functionalities include but are not limited to fluid transportation, mass transfer, heat transfer, energy harvest from and energy emission to the surrounding environment; signal communication and energy transportation.