Space-Aware 3D Printing of Vehicle Components with Hybrid Reinforcement
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Solution Overview
Problem
Existing 3D printing technologies face limitations in printing vehicle components due to size constraints and material differences, leading to inferior mechanical properties and inefficiencies in replacing conventional parts, with a need for enhanced flexibility and space-aware modeling.
Innovation Solution
A method for 3D printing vehicle components using a 3D model that accounts for mounting space limitations and material properties, allowing for flexible design and efficient production of functional replacements by segmenting and combining components, utilizing 3D bounding spaces and various printing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If 3D printing is used to produce vehicle components, then production speed and flexibility are improved, but mechanical strength and structural properties deteriorate compared to conventional manufacturing
Solution Approach 1:
The patent applies composite materials by combining 3D printed components with conventional manufactured components in a hybrid assembly. The 3D printed parts provide complex geometries and flexibility, while conventional manufactured parts provide high mechanical strength and structural integrity, resolving the contradiction between production flexibility and mechanical strength
Solution Approach 2:
The patent segments the vehicle component into multiple parts: a 3D printed body portion and a conventionally manufactured reinforcement portion. This segmentation allows each part to be optimized for its specific function - the 3D printed part for geometric complexity and the conventional part for mechanical strength
2Reliability
If 3D printed parts are designed to exactly match original components, then replacement compatibility is improved, but design flexibility and optimization opportunities are lost
Solution Approach 1:
The patent applies dynamics by making the 3D printed component adaptable and reconfigurable rather than a static copy. The component can be modified in shape, size, and internal structure to optimize for 3D printing processes while maintaining functional compatibility through standardized interfaces and mounting features
Solution Approach 2:
The patent applies local quality by applying different design approaches to different parts of the component. Critical interfaces and mounting areas maintain exact compatibility with original components, while non-critical areas are optimized for 3D printing with features like lattice structures, optimized wall thicknesses, and integrated mounting elements
3Strength
If material is added to 3D printed components to improve mechanical strength, then structural properties are improved, but mounting space requirements increase beyond available vehicle space
Solution Approach 1:
The patent applies another dimension by moving reinforcement features from external additions to internal structures. Instead of adding material externally which would increase mounting space, the reinforcement is placed internally through features like lattice structures, honeycomb patterns, and internal ribs that provide strength within the existing bounding box
Solution Approach 2:
The patent applies nested doll by placing reinforcement structures inside the 3D printed component. Internal ribs, lattice structures, and hollow chambers are nested within the component geometry, providing structural reinforcement without increasing the external dimensions or mounting space requirements
4Strength
If conventional manufacturing techniques are used for vehicle components, then mechanical strength is ensured, but production time and flexibility deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-designing hybrid components that combine 3D printed and conventional manufactured parts. The design phase prepares all necessary files, toolpaths, and assembly instructions in advance, allowing rapid production without sacrificing mechanical strength, thereby reducing production time compared to pure conventional manufacturing
Data Source
Figure 1A~1C
Figure 2~3A
Figure 3B
AI summary
The present disclosure relates to a computer implemented method for three-dimensional (3D) printing, for example for 3D printing spare parts (301) for a vehicle (100, 102, 104). The present disclosure also relates to a corresponding arrangement (200) and to a computer program product.