3D-Printed Space Frame Joints for Variable Tube Geometry
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Solution Overview
Problem
Traditional methods for fabricating joint members for space frame construction, such as welded tube frame chassis, incur high equipment and manufacturing costs due to the need for connecting tubes at various angles and geometries, limiting design flexibility and increasing production expenses.
Innovation Solution
A 3-D printing method is developed to fabricate joints that can accommodate various geometric parameters and stress directions, allowing for the connection of tubes with specific angles, sizes, and shapes, incorporating centering features and internal routing features for adhesive application and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fabrication methods are used for joint members, then manufacturing precision and structural integrity can be achieved, but manufacturing costs and equipment requirements increase significantly
Solution Approach 1:
The patent changes the manufacturing method from traditional subtractive or formative processes to additive manufacturing (3-D printing). This parameter change enables complex joint geometries to be manufactured directly from digital models, reducing tooling costs and equipment requirements while maintaining manufacturing precision through digital control of the printing process
Solution Approach 2:
The patent replaces traditional mechanical fabrication systems (CNC machines, molds, fixtures) with an additive manufacturing system. This substitution eliminates the need for expensive specialized equipment while achieving the required manufacturing precision through layer-by-layer material deposition controlled by computer-aided design files
2Strength
If traditional fabrication methods are used for joint members, then structural integrity can be maintained, but design flexibility and adaptability decrease
Solution Approach 1:
The patent introduces design flexibility by enabling joint members to be dynamically adapted to different tube configurations, angles, and geometries through digital modeling and 3-D printing. The system can quickly generate customized joint designs without retooling, allowing the structure to accommodate various design requirements while maintaining structural integrity through optimized geometry
Solution Approach 2:
The patent applies local quality optimization by using 3-D printing to create joint members with varying material distribution and density at different locations. The additive manufacturing process allows for optimized material placement in high-stress areas while reducing material in low-stress areas, achieving both structural integrity and design flexibility
3Manufacturing precision
If complex joint geometries are manufactured using traditional methods, then connection accuracy can be achieved, but manufacturing time and complexity increase
Solution Approach 1:
The patent applies preliminary action by creating accurate digital 3-D models of joint members before manufacturing. The computer-aided design files contain all geometric information and tolerances, which are then directly translated into the physical joint through 3-D printing. This preliminary digital preparation enables precise connection accuracy to be achieved without the time-consuming setup and adjustment required by traditional methods
Solution Approach 2:
The patent uses digital copying by creating virtual 3-D models that can be replicated and modified easily. The digital model serves as a master copy that can be adjusted for different joint requirements and then directly manufactured through 3-D printing, eliminating the need to recreate physical patterns or fixtures for each variation and significantly improving manufacturing speed
Data Source
AI summary
A method for fabricating a joint designed to connect tubes for a space frame, where a space frame may be a vehicle chassis, is provided. The method may generate joints with variable geometry and fine features which may reduce production costs, reduce production time, and generate joints configured for highly specific applications. The joint may include centering features which may create a space between a surface of the tube and a surface of the joint through which adhesive may flow.