AM-Sert

Designing joining zones with metal threaded inserts in additively manufactured components

A key challenge in the industrial use of additively manufactured fused layer modeling (FLM) components is the connection with other components and/or assemblies. However, established joining systems for thermoplastic components (e.g. metallic threaded inserts in injection molded components) and their design guidelines are only transferable to a limited extent, as they do not take into account the process-related inhomogeneous material structure and the anisotropic structure in the joining zone. The aim is therefore to develop a comprehensive understanding of the integration of metallic thread inserts in additively manufactured FLM components in order to overcome current application restrictions, increase the achievable joining properties and enable the design and layout of joining zones.

Based on the identification of suitable insertion technologies, the effects of process-related and geometric influencing factors on the joint properties are analyzed in extensive tests. In addition to the computed tomography-based structure and damage analysis, comparative studies on injection molding are also carried out and enable a direct comparison with established joining systems.

The high potential of metallic thread inserts in FLM components is also emphasized by the development of practice-relevant design guidelines, thus enabling users and constructors to develop and implement new solutions.