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DE-102024130950-A1 - Method for manufacturing a vehicle part, vehicle part and vehicle

DE102024130950A1DE 102024130950 A1DE102024130950 A1DE 102024130950A1DE-102024130950-A1

Abstract

A method for manufacturing a vehicle part (10) is proposed. The method comprises the following steps: • (S1) Applying a film (14), in particular an adhesion promoter film, to a carrier part (12), • (S2) Printing at least one geometric structure (18) onto the film (14) using a 3D printing process, wherein during the printing of the geometric structure (18) the film (14) melts at least partially and welds to the geometric structure (18).

Inventors

  • Christof Schönhammer
  • Stefan Hobelsberger

Assignees

  • BAYERISCHE MOTOREN WERKE AKTIENGESELLSCHAFT

Dates

Publication Date
20260513
Application Date
20241024

Claims (9)

  1. Method for manufacturing a vehicle part (10) comprising the following steps: • (S1) Applying a film (14), in particular an adhesion promoter film, to a carrier part (12), • (S2) Printing at least one geometric structure (18) onto the film (14) using a 3D printing process, wherein, during the printing of the geometric structure (18), the film (14) at least partially melts and welds to the geometric structure (18).
  2. Procedure according to Claim 1 , wherein the film (14) comprises polyamide, polyester and/or polypropylene.
  3. Method according to one of the preceding claims, wherein the film (14) is painted at least on one side.
  4. Method according to one of the preceding claims, wherein the carrier part (14) comprises natural fibers and/or a plastic.
  5. Method according to one of the preceding claims, wherein the film (14) is applied to the carrier part (12), in particular to a surface of the carrier part (12), by gluing, welding and/or pressing.
  6. Method according to one of the preceding claims, wherein the geometric structure (18) forms a functionalization element.
  7. Method according to one of the preceding claims, wherein the carrier part (12) and/or the film (14) is measured by means of a measuring unit before the geometric structure (18) is printed and wherein the geometric structure (18) is printed based on the measurement of the carrier part (12) together with the film (14).
  8. Vehicle part (10) which is manufactured according to a method according to one of the preceding claims.
  9. vehicle which at least one vehicle part according to Claim 8 exhibits.

Description

The invention relates generally to the field of vehicle parts. In particular, the invention relates to a method for manufacturing a vehicle part, a vehicle part, and a vehicle with such a vehicle part. In component manufacturing, the forming capabilities of semi-finished products are often limited, making it necessary to apply additional plastic elements, such as fasteners, protective elements, or decorative elements, to a substrate. The separate production of such elements and their subsequent application to a substrate can be very costly. In current technology, this is typically achieved by welding, bonding, or overmolding during the injection molding process. However, this entire process chain for manufacturing and applying the additional elements is very complex and requires significant investment in production infrastructure, such as equipment and tooling. Additional handling and pretreatment steps further increase manufacturing costs, especially for small production runs. The object of the present invention is to at least partially solve the aforementioned problems. In particular, the object of the present invention is to provide a method for manufacturing a vehicle part in which additional elements can be 3D-printed directly onto a substrate. Furthermore, the invention aims to provide a flexible and cost-effective method for manufacturing a vehicle part. The invention is defined in the independent claims. Advantageous embodiments of the invention are described in the dependent claims and the following description. A first aspect of the present disclosure relates to a method for manufacturing a vehicle part. The method comprises the following steps: • Applying a film, in particular an adhesion promoter film, to a substrate, • Printing at least one geometric structure onto the film using a 3D printing process. During the printing process, the film melts at least partially and fuses with the geometric structure. A method is proposed which, in a first step, involves applying a film to a substrate. Specifically, a film can be applied to a surface of the substrate to form a semi-finished product. The application of the film can be part of the overall manufacturing process of the semi-finished product. For example, the film can be applied to a surface of the substrate while the semi-finished product is being manufactured. The tool used to manufacture the semi-finished product can also be used to apply the film to the substrate. The film preferably comprises a first material. The substrate preferably comprises a second material that differs from the first material. The film can be liquid or viscous during application and can form a layer on a surface of the substrate, particularly by curing. The film can, in particular, completely cover a surface of the substrate. Alternatively, the film can be applied only to a first section of the substrate. The first section is preferably a section onto which a geometric structure is to be printed. To complete or manufacture the semi-finished product, the film and the substrate can be formed or deformed together. For example, the film can be pre-positioned on the substrate and applied to it using a compression molding process. Such a compression molding process can serve to deform both the film and the substrate. The film can therefore be applied to, or joined with, the substrate essentially simultaneously with its deformation. The deformed substrate together with the film can be referred to as a semi-finished product. This semi-finished product can therefore have a three-dimensional geometry. After applying the film, which can form a thin layer, in particular a surface layer of the substrate, at least one geometric structure is printed onto the film using a 3D printing process. This means that a geometric structure can be printed onto the semi-finished product, which already has a three-dimensional geometry. In particular, a three-dimensional structure is printed directly onto the film, for which an additive manufacturing process can be used. This means that the geometric structure can be printed directly onto the semi-finished product. In the context of this disclosure, 3D printing processes include, in particular, additive manufacturing processes. The geometric structure can serve to functionalize and/or personalize the semi-finished product, or the substrate including the film. The geometric structure can be referred to as an additional element. The semi-finished product can also be referred to as a substrate, with the semi-finished product with at least one geometric structure forming the vehicle part. By printing the geometric structure, the film, and in particular the contact surface between the film and the geometric structure, can at least partially melt and fuse with the geometric structure. A material-bonded connection between the film and the geometric structure can be created using the 3D printing process. This allows the geometric structure to be joined to t