Additively Manufactured Vibration Isolator Bellows With Lower Part Count
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Solution Overview
Problem
Existing vibration isolator assemblies face challenges such as high part counts, assembly complexities, costly fabrication of hermetically sealed bellows, and long cycle times due to manufacturing constraints, limiting their optimal configuration and efficiency.
Innovation Solution
The use of additive manufacturing techniques, specifically direct metal laser sintering (DMLS), allows for the creation of vibration isolator assemblies with variable aspect ratios and complex designs without the need for traditional tooling, reducing part counts and cycle times while enabling optimized damper/spring assemblies with variable wall thicknesses and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional roll-forming or expansive-forming techniques are used to manufacture bellows, then the manufacturing process is well-established and reliable, but the geometry is limited to circumferential or round shapes and the part count increases
Solution Approach 1:
The patent combines multiple separate components (bellows, piston, shaft, housing) into a single monolithic structure manufactured via additive manufacturing. This merging eliminates the need for traditional separate part fabrication and assembly, directly reducing part count while enabling complex geometries that would be impossible with conventional roll-forming or expansive-forming techniques.
Solution Approach 2:
The patent utilizes additive manufacturing to change the geometric parameters of the bellows, enabling variable aspect ratios and complex three-dimensional shapes that cannot be achieved with traditional forming methods. This parameter change allows optimization of the bellows geometry for specific performance requirements while maintaining structural integrity.
2Reliability
If hermetically sealed bellows are fabricated using traditional methods, then pressure containment is achieved, but fabrication cost and cycle time increase
Solution Approach 1:
By manufacturing the bellows as part of a monolithic structure with integrated sealing features, the patent eliminates separate sealing components and assembly steps. The sealing functionality is built-in during the additive manufacturing process, maintaining pressure containment reliability while dramatically reducing fabrication cycle time and cost.
Solution Approach 2:
The additive manufacturing process creates self-contained sealing structures within the monolithic assembly. The design incorporates self-sealing features where the geometry itself provides the sealing function, eliminating the need for additional sealing components or complex assembly procedures to achieve hermetic sealing.
3Ease of manufacture
If traditional manufacturing constraints are followed, then manufacturing is simplified, but optimal configuration is limited
Solution Approach 1:
The patent leverages additive manufacturing to change the fundamental parameters of what can be manufactured, allowing variable wall thicknesses, variable aspect ratios, and complex internal geometries. These parameter changes enable configuration optimization for specific performance requirements without increasing manufacturing complexity, as the additive process inherently handles complex geometries.
Solution Approach 2:
The monolithic structure manufactured via additive manufacturing allows for local optimization of properties throughout the assembly. Different regions can have different wall thicknesses, material densities, or structural characteristics tailored to local performance requirements, enabling configuration optimization that would be impossible with traditional uniform manufacturing methods.
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 approach results in a lower-cost, more robust, and faster-to-produce vibration isolator assembly with reduced variability and defects, capable of complex geometries not achievable with traditional methods, optimizing performance and reliability.
Implementation Method 1
additive manufacturing techniques, specifically direct metal laser sintering (DMLS)
Implementation Method 2
direct metal laser sintering (DMLS)
Data Source
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AI summary
A vibration isolator assembly (106) includes a bellows component (120, 122), a piston component (124), a shaft component (176), and a housing component (118), wherein at least one of the bellows component (120, 122), the piston component (124), the shaft component (176), and the housing component (118) is formed using additive manufacturing techniques.