Method of assembly for 3d printed vehicle architecture, joints

Patent metadata

Field	Value
Publication number	US-2020016830-A1
Application number	US-201816490659-A
Country	US
Kind code	A1
Filing date	Mar 1, 2018
Priority date	Mar 1, 2017
Publication date	Jan 16, 2020
Grant date	—

Abstract

A method of assembling components of a vehicle is provided that includes locating a node (20) relative to an adjoining component (22), measuring at least one geometrical feature of the node or the adjoining component, 3D printing an assembly adjustment member (24) based on the measuring, and placing the assembly adjustment member proximate at least one of the node or the adjoining component. The assembly adjustment member is configured to allow relative movement between the node and the adjoining component for subsequent processing operations.

First claim

What is claimed is:

1 . A method of assembly comprising:
locating a node relative to an adjoining component; measuring at least one geometrical feature of the node or the adjoining component; 3D printing an assembly adjustment member based on the measuring; and placing the assembly adjustment member proximate at least one of the node or the adjoining component, wherein the assembly adjustment member is configured to allow relative movement between the node and the adjoining component for subsequent processing operations.

2 . The method according to claim 1 , wherein the 3D printing is performed in-situ with the method of assembling.

3 . The method according to claim 1 , wherein the 3D printing is performed offline and the assembly adjustment member is prefabricated.

4 . The method according to claim 3 , wherein the assembly adjustment member is selected from a library of standard assembly adjustment members.

5 . The method according to claim 1 , wherein the assembly adjustment member is disposed between the node and the adjoining component.

6 . The method according to claim 1 further comprising:
fabricating the node with at least one tooling feature; and
placing a component blank onto the node and locating the component blank with the at least one tooling feature,
wherein the assembly adjustment member is printed onto the component blank.

7 . The method according to claim 1 , wherein at least one of the node and the adjoining component are formed by a 3D printing process.

8 . The method according to claim 1 , wherein the adjoining component defines an insert that is disposed at least partially within a hollow space of the node.

9 . The method according to claim 8 , wherein the hollow space of the node is at least partially filled with an adhesive after the subsequent processing operations.

10 . The method according to claim 9 , wherein the adhesive is injected into the hollow space of the node through an injection port.

11 . The method according to claim 8 , further comprising mechanically securing the adjoining component within the node after the subsequent processing operations.

12 . The method according to claim 1 , wherein the node further comprises a tapered outer geometry configured to provide additional relative movement between the node and the adjoining component.

13 . The method according to claim 1 , wherein the subsequent processing operations are selected from the group consisting of an electrophoretic coating (E-Coat) process, paint, and surface coating processes.

14 . The method according to claim 1 , wherein a plurality of nodes and a plurality of adjoining components are measured, and the 3D printed assembly adjustment members are paired with closest mating geometries of nodes and adjoining components.
wherein the assembly adjustment member is configured to allow relative movement between the node and the adjoining component for subsequent processing operations.

15 . The method according to claim 1 , wherein the node is an organic node that is optimized for design load conditions and is formed by a 3D printing process, the node defining at least one receiving portion and an outer geometry that is configured elastically, and up to plastically, deform for fit-up of the node to the adjoining component.

Assignees

• Ford Global Tech Llc

Inventors

• Huff Garret
• Whitens Michael James
• Friedman Peter A
• Flanigan Cynthia Mowery

Classifications

• F16B11/008 Primary

  of tubular elements or rods in coaxial engagement · CPC title

• B29C64/176 Primary

  Sequentially · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29C64/00

  Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title