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Article

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

Institute of Automotive Technology, TUM School of Engineering and Design, Technical University of Munich, Boltzmannstraße 15, 85748 Garching, Germany
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Academic Editor: Mahdi Bodaghi
Received: 26 November 2021 / Revised: 23 December 2021 / Accepted: 24 December 2021 / Published: 29 December 2021
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. View Full-Text
Keywords: design method; joint design; segmentation; additive manufacturing; rapid prototyping; fused deposition modeling (FDM) design method; joint design; segmentation; additive manufacturing; rapid prototyping; fused deposition modeling (FDM)
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MDPI and ACS Style

König, N.; Schockenhoff, F.; König, A.; Diermeyer, F. Method for Segmentation and Hybrid Joining of Additive Manufactured Segments in Prototyping Using the Example of Trim Parts. Designs 2022, 6, 2. https://doi.org/10.3390/designs6010002

AMA Style

König N, Schockenhoff F, König A, Diermeyer F. Method for Segmentation and Hybrid Joining of Additive Manufactured Segments in Prototyping Using the Example of Trim Parts. Designs. 2022; 6(1):2. https://doi.org/10.3390/designs6010002

Chicago/Turabian Style

König, Nils, Ferdinand Schockenhoff, Adrian König, and Frank Diermeyer. 2022. "Method for Segmentation and Hybrid Joining of Additive Manufactured Segments in Prototyping Using the Example of Trim Parts" Designs 6, no. 1: 2. https://doi.org/10.3390/designs6010002

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