Tongue-and-Groove Node Assembly for Large 3D-Printed Components
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Solution Overview
Problem
Current additive manufacturing techniques face limitations in joining large components, such as gear cases, due to size constraints of 3D printers, necessitating labor-intensive traditional methods like welding or machining, and struggle to integrate subcomponents for fluid transport without leakage.
Innovation Solution
The use of additively manufactured tongue-and-groove connections between subcomponents, facilitated by adhesive and vacuum infusion, allows for efficient and durable assembly of complex geometries, eliminating the need for additional joining processes like welding and ensuring reliable fluid transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding or machining techniques are used to join components, then structural integrity is achieved, but labor intensity and manufacturing cost increase significantly
Solution Approach 1:
The patent replaces traditional mechanical joining methods (welding, riveting, machining) with adhesive bonding. The adhesive application system automatically applies adhesive between components, eliminating the need for manual welding or machining operations while maintaining structural integrity through chemical bonding.
Solution Approach 2:
The system enables self-aligned assembly where components with complementary geometric features (protrusions and recesses) automatically guide and position themselves during assembly. The adhesive bonding process allows components to be joined without complex fixturing or alignment procedures required by traditional methods.
2Strength
If components are designed as single large pieces, then structural integrity is maintained, but additive manufacturing size constraints prevent production
Solution Approach 1:
The patent divides large components into multiple smaller subcomponents that can be individually manufactured within additive manufacturing size constraints. These subcomponents are then joined using adhesive bonding to form the complete assembly, achieving both manufacturability and structural integrity.
Solution Approach 2:
The system combines multiple additively manufactured subcomponents into a single functional assembly through adhesive bonding. The geometric features (protrusions and recesses) ensure proper alignment and integration of subcomponents, creating a unified structure that functions as a single component.
3Adaptability or versatility
If subcomponents are assembled for fluid transport, then manufacturing flexibility is improved, but leakage risks increase
Solution Approach 1:
The patent incorporates sealing features at specific locations where subcomponents join. The adhesive bonding is applied in controlled patterns to ensure complete sealing of fluid pathways, while allowing other areas to maintain manufacturing flexibility. The geometric features are designed with sealing surfaces that ensure leak-free connections.
4Manufacturing precision
If traditional machining techniques are used, then manufacturing precision is achieved, but production time and cost increase
Solution Approach 1:
The patent replaces traditional machining operations with additive manufacturing followed by adhesive bonding. The additive process directly creates components with required geometric precision, eliminating time-consuming machining operations while maintaining dimensional accuracy through controlled adhesive application and positioning features.
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 method enables the construction of lightweight, complex components with precise specifications, reducing material waste and operational costs while ensuring structural integrity and fluid sealing, overcoming size limitations and assembly challenges of traditional methods.
Implementation Method 1
The tongue structure is configured to mate with the groove structure along the first and second peripheral regions
Implementation Method 2
facilitated by adhesive and vacuum infusion
Data Source
AI summary
Techniques for joining nodes and subcomponents are presented herein. An additively manufactured first node or subcomponent has a groove. An additively manufactured second node or subcomponent has a tongue configured to extend into and mate with the groove to form a tongue-and-groove connection between the first and second node or subcomponent. In some aspects, the tongue-groove connection may extend substantially around a periphery of the node or subcomponent. In other aspects, a first subcomponent having a fluid pipe interface may be coupled via a tongue-groove connection to a second subcomponent having a fluid pipe interface, thereby enabling fluid to flow between subcomponents of the resulting integrated component.