US Patent 9463829 Elastically averaged alignment systems and methods

In one aspect, an elastically averaged alignment system includes a first component having an interior cavity and an alignment member positioned at least partially within the interior cavity, a second component having an inner wall defining an alignment aperture, the alignment aperture configured to receive the alignment member to couple the first component and the second component, and a third component seated within the interior cavity. The alignment member is an elastically deformable material such that (a) when the third component is inserted into the interior cavity, the alignment member elastically deforms to an elastically averaged configuration to facilitate aligning the third component and the first component in a desired orientation, and (b) when the alignment member is inserted into the alignment aperture, the alignment member further elastically deforms to an elastically averaged final configuration to facilitate aligning the first component and the second component in a desired orientation.