Structural Component Bonding With Embedded Supplementary Profiles

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Solution Overview

Problem

Existing additive manufacturing methods struggle to stably connect structural components to other components or fasten attachment parts due to the mechanical and anisotropic properties of additively manufactured materials.

Innovation Solution

The method involves building a structural component layer by layer, positioning a supplementary profile on the base body, and fastening it through substance-to-substance bonding, allowing for improved local fastening and functional properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If additive manufacturing methods are used to build structural components layer by layer, then generative production capability is improved, but mechanical properties and fastening capability deteriorate due to anisotropic structure

Engineering Contradiction:

Improvegenerative production capabilityVSAvoidmechanical properties and fastening capability

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent applies local quality by integrating a supplementary profile with different material properties into specific regions of the additively manufactured base body. The supplementary profile is positioned in regions requiring enhanced mechanical properties or fastening capability, while the base body maintains its generatively manufactured structure in other areas. This allows local optimization of mechanical properties without compromising the overall generative production advantage.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining the additively manufactured base body with a supplementary profile made of different material (e.g., metal profile in plastic base body or vice versa). This composite structure leverages the advantages of both materials: the base body provides generative production capability and complex geometry, while the supplementary profile provides enhanced mechanical strength and fastening properties.

Inventive Principle:

Principle #40Composite materials

2Strength

If interruption of layer building occurs to integrate supplementary profile, then local fastening capability is improved, but manufacturing time and process complexity increase

Engineering Contradiction:

Improvelocal fastening capabilityVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-fabricating the supplementary profile separately before integrating it into the base body during the additive manufacturing process. The supplementary profile is prepared in advance with its specific geometry and material properties, allowing for efficient integration at the appropriate stage without requiring complex real-time modifications to the layer building process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The supplementary profile acts as an intermediary element that bridges the gap between the additively manufactured base body and external fastening requirements. It provides a standardized interface for fastening operations while maintaining compatibility with the base body's geometry and material, simplifying the overall manufacturing process despite the interruption in layer building.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If homogeneous material structure is used throughout the structural component, then material consistency is improved, but local functional properties and fastening possibilities deteriorate

Engineering Contradiction:

Improvematerial consistencyVSAvoidlocal functional properties and fastening possibilities

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The patent applies local quality by introducing a supplementary profile with different material properties into specific regions of the base body where enhanced functional properties or fastening capability are required. The base body maintains homogeneous material structure for ease of manufacture, while the supplementary profile provides localized adaptation for specific functions such as fastening, thermal management, or structural reinforcement.

Inventive Principle:

Principle #3Local quality

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 the creation of structural components with enhanced local fastening capabilities and functional properties, addressing the challenges of mechanical and anisotropic properties in additive manufacturing.

Implementation Method 1

building a first base body layer by layer, fastening the supplementary profile to the first base body by substance-to-substance bonding, and building a second base body layer by layer so as to continue the formation by substance-to-substance bonding

Methodology Applied

Scientific EffectSubstance-to-substance bonding: Welding

Implementation Method 2

The system has a heating unit, in particular a laser unit, which is configured to heat the material and/or the supplementary profile

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS20250178128A1Method and System for Producing a Structural Component

Publication Date: 2025.06.05 BAYERISCHE MOTOREN WERKE AG

AI summary

A method for producing a structural component includes building a first base body layer by layer, positioning a supplementary profile on the first base body, and building a second base body layer by layer. The method further includes fastening the supplementary profile to the first base body and to the second base body by substance-to-substance bonding while enclosing the supplementary profile at least partially between the first base body and the second base body.