3D Printed Automotive Trim Attachment Element Adhesion
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Solution Overview
Problem
Current methods for producing automotive interior equipment components require additional steps and tools for attachment, leading to increased costs and complexity, especially in achieving strong and precise adhesion of attachment elements to the base body.
Innovation Solution
A method where the base body is heated in the region where the attachment element is printed, using a 3D printing method with polymeric plastic, allowing for improved adhesion and eliminating rapid cooling issues, enabling the production of attachment elements that can be freely formed and colored, and optionally integrated into the base body with a temperature gradient for enhanced precision and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If attachment elements are manufactured separately using injection molds or extrusion dies and then attached to the base body, then the attachment elements can be produced with consistent quality, but the production process becomes complex and costly due to additional tools and steps
Solution Approach 1:
The patent merges the manufacturing of the base body and attachment elements into a single 3D printing process. The attachment elements are printed directly onto the base body in the same production run, eliminating the need for separate injection molds, extrusion dies, and subsequent attachment steps. This consolidation reduces tooling complexity and streamlines the manufacturing process.
Solution Approach 2:
The 3D printing system serves multiple functions: it manufactures the base body, creates the attachment elements, and bonds them together in a single operation. This multi-functional approach replaces the traditional multi-step process that required separate tooling for each component, reducing overall device complexity.
2Productivity
If attachment elements are attached using welding, gluing, or mechanical fastening methods, then the components can be joined, but additional processing steps and materials are required
Solution Approach 1:
The manufacturing and attachment operations are merged into a single 3D printing process. The attachment elements are deposited directly onto the base body and bond during the printing process itself, eliminating separate welding, gluing, or fastening steps. This reduces process complexity and improves production efficiency.
3Strength
If the base body is not heated before printing the attachment element, then the manufacturing process is simpler, but the adhesion of the attachment element to the base body is insufficient
Solution Approach 1:
The base body is pre-heated in the specific area where the attachment element will be printed, before the actual printing begins. This preliminary heating action ensures optimal adhesion conditions are established in advance, allowing the attachment element to bond strongly without requiring excessive energy during the printing process itself.
Solution Approach 2:
Heating is applied locally only to the specific area of the base body where the attachment element will be deposited, rather than heating the entire base body. This localized heating approach achieves sufficient adhesion strength while minimizing overall energy consumption.
4Manufacturing precision
If the material for the attachment element cools rapidly after application, then the printing process is faster, but defects occur in the attachment element
Solution Approach 1:
The base body area is pre-heated before printing, creating a thermal buffer that prevents rapid cooling of the deposited material. This preliminary thermal preparation allows the attachment element to cool slowly and uniformly, avoiding defects while maintaining printing speed.
Solution Approach 2:
The temperature parameters of the base body are dynamically adjusted during the printing process. The base body is heated to specific temperatures before printing and maintained at appropriate thermal levels during printing, controlling the cooling rate of the attachment element material to prevent defects while preserving production efficiency.
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 simplifies the production of automotive interior components by reducing tool costs, enabling cost-effective, precise, and adaptable attachment elements that can be produced in series or individually, with improved connection strength and design flexibility, allowing for better integration with the base body and reduced development costs.
Implementation Method 1
the base body is heated, at least in the area where the attachment element is printed, before the attachment element is printed on it
Data Source
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AI summary
The invention relates to a method for producing a motor vehicle interior trim component (1) consisting of a main part (6) with an upper side (3) and a lower side (4), wherein an attachment element (2) based on at least one polymer plastic is arranged on said main part (6) and is produced in a 3D printing method. The invention also relates to a motor vehicle interior trim component (1) produced using the method, and to the use of a 3D printer.