Monolithic Trim Article With Variable Lattice Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle component parts require multiple materials to achieve varied density profiles, which complicates manufacturing and increases complexity, whereas a single material solution using additive manufacturing techniques is desired to simplify production while maintaining performance.
Innovation Solution
A method involving the creation of trim articles using a single material through additive manufacturing, where a design envelope is created with lattice matrices of varying density profiles to replicate the performance of multi-material components, allowing for the formation of monolithic structures with specific density profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple materials are used to achieve varied density profiles, then the density profile requirement is met, but the manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by varying the density of a single material through additive manufacturing parameters (infill percentage, lattice structure density) rather than changing materials. The system achieves different density profiles (e.g., 20% in outer regions, 80% in inner regions) by adjusting printing parameters during the additive manufacturing process, thus meeting density requirements without multi-material complexity
Solution Approach 2:
The patent uses a single homogeneous material throughout the component while creating internal heterogeneity through varied lattice structures and infill patterns. This approach maintains material simplicity (single polymer or metal) while achieving functional density variation through geometric configuration rather than material composition
2Manufacturing precision
If multiple materials are used to achieve varied density profiles, then the density profile requirement is met, but the number of manufacturing steps increases
Solution Approach 1:
The patent merges multiple manufacturing operations into a single additive manufacturing process. Instead of separately manufacturing different density regions with different materials and then assembling them, the system prints the entire multi-density component in one continuous process, integrating what would traditionally be multiple steps into a single operation
Solution Approach 2:
The patent performs preliminary digital modeling and slicing that pre-calculates all density variations before manufacturing. The support structures, lattice patterns, and infill densities are all predetermined in the digital model, allowing the physical manufacturing to proceed without mid-process material changes or additional assembly steps
3Ease of manufacture
If a single material is used, then the manufacturing process is simplified, but achieving varied density profiles becomes more difficult
Solution Approach 1:
The patent overcomes the limitation of single-material density control by dynamically changing manufacturing parameters during the additive process. By adjusting infill percentage, lattice cell size, and layer density as printing progresses, the system achieves precise density profiles (e.g., transitioning from 20% to 80% density) while maintaining material homogeneity and process simplicity
Solution Approach 2:
The patent solves the density control problem by adding a geometric dimension to material properties. Instead of varying material composition, the system varies the geometric configuration of the lattice structures and infill patterns, creating density variation through spatial arrangement rather than material differentiation
Data Source
AI summary
A method of making a trim article includes the steps of 1) obtaining specified criteria of a target component part comprised of a plurality of materials; 2) processing the specified criteria into a design envelope that includes parameters of the target component part within which the trim article to be created is to be confined, 3) inputting the design envelope into an additive manufacturing device supplied with a single forming material; and 4) forming the trim article using the additive manufacturing device from the single material. The formed trim article includes an outer casing with an interior portion having one or more lattice matrices disposed therein and having varying density profiles to simulate the specified criteria of the target component part. The formed trim article is created as a fully integrated monolithic whole via the additive manufacturing device.