AM-Sert
Requirements-based design of joining zones with inserts in additively man-ufactured components
Project duration
From: 01.03.2023 To: 30.06.2025Description
Abstract
The project Requirements-based design of joining zones with inserts in additively man-ufactured components will first select suitable plastics such as PLA, ABS, PA, and PC and comprehensively characterize their properties in order to create the basis for additive manufacturing and the integration of inserts. Building on this, test specimens will be developed that take into account different printing parameters, build directions, and geometries. At the same time, commercially available inserts will be integrated using various insertion methods such as ultrasound, hot embedding, self-cutting, and expan-sion anchoring. Suitable process parameters will be determined for all variants to ensure reproducible results.
The manufactured test specimens will then be mechanically tested to determine tensile strengths, torques, and load limits. In addition, structural and damage analyses are per-formed using micrographs and computed tomography to evaluate the quality of the joint zones and possible damage. The findings are incorporated into simulation-based optimizations, which enable efficient design of the joint zones and reduce the amount of practical testing required. In addition, comparative studies with granulate pressure and injection molding processes are carried out in order to classify the results and create a sound basis for design guidelines.
Finally, all data and correlations obtained will be processed and summarized in the form of guidelines for the design and layout of joining zones with inserts in additively manu-factured components. These guidelines are intended to enable companies, especially SMEs, to use the technology safely and economically, while also forming the basis for standardization activities and future standards.
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