Modular Vehicle Chassis Joints Using 3D-Printed Node Connectors

The patent changes the manufacturing method parameter from traditional subtractive or formative processes to additive manufacturing (3-D printing). This enables complex joint geometries to be fabricated directly from digital models, maintaining precision while eliminating expensive tooling and equipment requirements. The additive process allows for precise control of material deposition and joint geometry without the high costs associated with traditional fabrication methods.

The patent transitions from two-dimensional planar elements to three-dimensional printed joints with complex spatial geometries. The 3-D printing process enables joints with multi-axis features, internal channels, and optimized structural topologies that cannot be achieved with planar elements. This dimensional enhancement provides significant design flexibility while maintaining manufacturing simplicity through digital fabrication processes.

The patent replaces the mechanical tooling system (molds, dies, and forming equipment) with a digital additive manufacturing system. Instead of requiring expensive physical tooling to create shaped panels, the design is directly fabricated through 3-D printing layer by layer from digital models. This substitution eliminates tooling costs entirely while maintaining the ability to produce complex shaped panels and integrated joints.

The 3-D printing process incorporates self-correction and self-verification mechanisms through automated monitoring systems that track material deposition, layer alignment, and dimensional accuracy in real-time. The digital model serves as a self-check reference, allowing the system to detect and compensate for deviations during fabrication. This self-service capability ensures manufacturing precision is maintained while benefiting from the cost and flexibility advantages of additive manufacturing.