Method for Segmentation and Hybrid Joining of Additive Manufactured Segments in Prototyping Using the Example of Trim Parts

Nils König,Adrian König,Frank Diermeyer,Ferdinand Schockenhoff

doi:10.3390/designs6010002

Abstract

Rapid prototyping has become increasingly popular over the past years. However, its application is heavily confined to a part size that fits the small build volume of additive machines. This paper presents a universal design method to overcome this limitation while preserving the economic advantages of rapid prototyping over conventional processes. It segments large, thin-walled parts and joins the segments. The method aims to produce an assembly with minimal loss to the performance and characteristics of a solid part. Based on a set of requirements, a universal segmentation approach and a novel hybrid joint design combining adhesive bonding and press fitting are developed. This design allows for the force transmission, positioning, and assembly of the segments adaptive to their individual geometry. The method is tailored to fused deposition modeling (FDM) by minimizing the need for support structures and actively compensating for manufacturing tolerances. While a universal application cannot be guaranteed, the adaptive design was proven for a variety of complex geometries. Using automotive trim parts as an example, the usability, benefits, and novelty of the design method is presented. The method itself shows a high potential to overcome the build volume limitation for thin-walled parts in an economic manner.

Highlights

Nowadays, customers have a growing desire for more individual and up-to-date products [1,2,3]
We present a method that achieves the universal segmentation of a large part, additive manufacturing of each segment and the subsequent joining of those, using a novel hybrid joint design in this paper
This paper focused on the segmentation of parts that fit in a cubic space with arbitrary length and width, but height limited to the width of the build volume of the additive manufacturing machine (Section 4.6)

Summary

Introduction

Customers have a growing desire for more individual and up-to-date products [1,2,3]. Products are characterized by an ever-shorter product life cycle. The simultaneous fulfillment of constantly growing standards puts product development under enormous time and cost pressure. Concepts in the form of prototypes have the potential to accelerate the generation of new products by identifying problems early on in their development [4] Cost- and time-intensive processes in conventional prototyping limit this potential. To overcome those barriers, the development of new design methods that accelerate the creation of prototypes are needed [5] The development of new design methods that accelerate the creation of prototypes are needed [5] (p. 280)

Objectives

Methods

Conclusion