# Patent

## Title
Self-retaining alignment system for providing precise alignment and retention of components

## Abstract

An elastically averaging self-retaining alignment system includes a first component and a second component. The first component includes a first alignment member and an elastically deformable alignment element fixedly disposed with respect to the first alignment member, the alignment element having a hollow tube. The second component includes a second alignment member and an alignment feature fixedly disposed with respect to the second alignment member, the alignment feature having an aperture with a plurality of inwardly extending tabs. The elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage the alignment feature. Portions of the elastically deformable alignment element when inserted into the alignment feature elastically deform to an elastically averaged final configuration that aligns and retains the first component relative to the second component in at least two of four planar orthogonal directions.

## Background
FIELD OF THE INVENTION
The subject invention relates to the art of alignment systems, more particularly to a self-retaining elastically averaged alignment system, and even more particularly to a self-retaining elastically averaged alignment system providing two-way and/or four-way alignment between a sheet metal stamping and a plastic component.
BACKGROUND
Currently, components, particularly vehicular components such as those found in automotive vehicles, which are to be mated together in a manufacturing process are mutually located with respect to each other by alignment features that are oversized and/or undersized to provide spacing to freely move the components relative to one another to align them without creating an interference therebetween that would hinder the manufacturing process. One example includes two-way and/or four-way male alignment features, typically upstanding bosses, which are received into corresponding female alignment features, typically apertures in the form of holes or slots. There is a clearance between the male alignment features and their respective female alignment features which is predetermined to match anticipated size and positional variation tolerances of the male and female alignment features as a result of manufacturing (or fabrication) variances. As a result, significant positional variation can occur between the mated first and second components having the aforementioned alignment features, which may contribute to the presence of undesirably large variation in their alignment, particularly with regard to the gaps and spacing between them. In the case where these misaligned components are also part of another assembly, such misalignments can also affect the function and/or aesthetic appearance of the entire assembly. Regardless of whether such misalignment is limited to two components or an entire assembly, it can negatively affect function and result in a perception of poor quality.
To align and secure components, the aforementioned male and female alignment features may be employed in combination with separate fastener components or a separate operation such as heat staking, for example, that serve to secure the components to each other. In such an assembly, the mating components are located relative to each other by the alignment features, and are fixed relative to each other by the separate fastener components. Use of separate alignment features and fastener components, one for alignment and the other for securement, may limit the effectiveness of each on a given assembly, as the alignment features cannot be employed where the fastener components are employed. Also, where heat staking is employed to fasten a metal component to a plastic component, the heat stake tool is typically designed to have a clearance to the metal component in order to avoid damage to the heat stake tool. With such a clearance, however, the resulting heat stake typically does not hold the metal component tight against the plastic component, which tends to produce a loosened assembly over time, requiring additional noise mitigation to be added to the assembly.
Accordingly, the art of alignment systems can be enhanced by providing a self-retaining alignment system or mechanism that can ensure precise two-way and/or four-way alignment and fastening of two components via elastic averaging of a single elastically deformable alignment element disposed in mating engagement with a corresponding single alignment and retention feature.
SUMMARY OF THE INVENTION
In an exemplary embodiment of the invention, an elastically averaging self-retaining alignment system is provided having a first component and a second component. The first component includes a first alignment member and an elastically deformable alignment element fixedly disposed with respect to the first alignment member, the alignment element having a hollow tube. The second component includes a second alignment member and an alignment feature fixedly disposed with respect to the second alignment member, the alignment feature having an aperture with a plurality of inwardly extending tabs. The elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage the alignment feature. Portions of the elastically deformable alignment element when inserted into the alignment feature elastically deform to an elastically averaged final configuration that aligns and retains the first component relative to the second component in at least two of four planar orthogonal directions.
The above features and advantages and other features and advantages of the invention are readily apparent from the following detailed description of the invention when taken in connection with the accompanying drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
Other features, advantages and details appear, by way of example only, in the following detailed description of embodiments, the detailed description referring to the drawings in which:
FIG. 1 depicts a perspective view of a disassembled elastically averaging self-retaining alignment system having first and second components, in accordance with an embodiment of the invention;
FIG. 2 depicts a front plan view of the elastically averaging self-retaining alignment system of FIG. 1 with the first and second components in an assembled state, in accordance with an embodiment of the invention;
FIG. 3 depicts an expanded perspective view of detail 300 in FIG. 2 with the first and second components in an assembled state, in accordance with an embodiment of the invention;
FIG. 4. depicts a front plan view of detail 300 of FIGS. 2 and 3 with the first and second components in a disassembled state just prior to engagement, in accordance with an embodiment of the invention;
FIG. 5 depicts a section view through cut line 5-5 of FIG. 4 in an assembled state, in accordance with an embodiment of the invention;
FIG. 6 depicts a section view through cut line 6-6 of FIG. 4 in an assembled state, in accordance with an embodiment of the invention; and
FIG. 7 depicts a front plan view similar to that of FIG. 4, but with an alternative detail 300a, in accordance with an embodiment of the invention.



DESCRIPTION OF THE EMBODIMENTS
The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. For example, the embodiments shown comprise vehicle components but the alignment system may be used with any suitable components to provide elastic averaging for precision location and alignment of all manner of mating components and component applications, including many industrial, consumer product (e.g., consumer electronics, various appliances and the like), transportation, energy and aerospace applications, and particularly including many other types of vehicular components and applications, such as various interior, exterior and under hood vehicular components and applications. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
As used herein, the term “elastically deformable” refers to components, or portions of components, including component features, comprising materials having a generally elastic deformation characteristic, wherein the material is configured to undergo a resiliently reversible change in its shape, size, or both, in response to application of a force. The force causing the resiliently reversible or elastic deformation of the material may include a tensile, compressive, shear, bending or torsional force, or various combinations of these forces. The elastically deformable materials may exhibit linear elastic deformation, for example that described according to Hooke's law, or non-linear elastic deformation.
Elastic averaging provides elastic deformation of the interface(s) between mated components, wherein the average deformation provides a precise alignment, the manufacturing positional variance being minimized to Xmin, defined by Xmin=X/√N, wherein X is the manufacturing positional variance of the locating features of the mated components and N is the number of features inserted. To obtain elastic averaging, an elastically deformable component is configured to have at least one feature and its contact surface(s) that is over-constrained and provides an interference fit with a mating feature of another component and its contact surface(s). The over-constrained condition and interference fit resiliently reversibly (elastically) deforms at least one of the at least one feature or the mating feature, or both features. The resiliently reversible nature of these features of the components allows repeatable insertion and withdrawal of the components that facilitates their assembly and disassembly. Positional variance of the components may result in varying forces being applied over regions of the contact surfaces that are over-constrained and engaged during insertion of the component in an interference condition. It is to be appreciated that a single inserted component may be elastically averaged with respect to a length of the perimeter of the component. The principles of elastic averaging are described in detail in commonly owned, co-pending U.S. patent application Ser. No. 13/187,675, now U.S. Publication No. 2013-0019455A1, the disclosure of which is incorporated by reference herein in its entirety. The embodiments disclosed above provide the ability to convert an existing component that is not compatible with the above-described elastic averaging principles, or that would be further aided with the inclusion of a self-retaining elastic averaging alignment system as herein disclosed, to an assembly that does facilitate elastic averaging and the benefits associated therewith.
Any suitable elastically deformable material may be used for the mating components and alignment features disclosed herein and discussed further below, particularly those materials that are elastically deformable when formed into the features described herein. This includes various metals, polymers, ceramics, inorganic materials or glasses, or composites of any of the aforementioned materials, or any other combinations thereof suitable for a purpose disclosed herein. Many composite materials are envisioned, including various filled polymers, including glass, ceramic, metal and inorganic material filled polymers, particularly glass, metal, ceramic, inorganic or carbon fiber filled polymers. Any suitable filler morphology may be employed, including all shapes and sizes of particulates or fibers. More particularly any suitable type of fiber may be used, including continuous and discontinuous fibers, woven and unwoven cloths, felts or tows, or a combination thereof. Any suitable metal may be used, including various grades and alloys of steel, cast iron, aluminum, magnesium or titanium, or composites thereof, or any other combinations thereof. Polymers may include both thermoplastic polymers or thermoset polymers, or composites thereof, or any other combinations thereof, including a wide variety of co-polymers and polymer blends. In one embodiment, a preferred plastic material is one having elastic properties so as to deform elastically without fracture, as for example, a material comprising an acrylonitrile butadiene styrene (ABS) polymer, and more particularly a polycarbonate ABS polymer blend (PC/ABS). The material may be in any form and formed or manufactured by any suitable process, including stamped or formed metal, composite or other sheets, forgings, extruded parts, pressed parts, castings, or molded parts and the like, to include the deformable features described herein. The elastically deformable alignment features and associated component may be formed in any suitable manner. For example, the elastically deformable alignment features and the associated component may be integrally formed, or they may be formed entirely separately and subsequently attached together. When integrally formed, they may be formed as a single part from a plastic injection molding machine, for example. When formed separately, they may be formed from different materials to provide a predetermined elastic response characteristic, for example. The material, or materials, may be selected to provide a predetermined elastic response characteristic of any or all of the elastically deformable alignment features, the associated component, or the mating component. The predetermined elastic response characteristic may include, for example, a predetermined elastic modulus.
As used herein, the term vehicle is not limited to just an automobile, truck, van or sport utility vehicle, but includes any self-propelled or towed conveyance suitable for transporting a burden.
In accordance with an exemplary embodiment of the invention, and with reference to FIG. 1, an elastically averaging alignment system 10 includes a first component 100 having a first alignment member 102 and an elastically deformable alignment element 104 in the form of a hollow tube (also herein referred to by reference numeral 104) fixedly disposed with respect to the first alignment member 102, and a second component 200 having a second alignment member 202 and an alignment feature 204 in the form of an aperture (also herein referred to by reference numeral 204) having a plurality of inwardly extending tabs 206 (best seen with reference to FIGS. 3 and 4) fixedly disposed with respect to the second alignment member 202. The aperture 204 with inwardly extending tabs 206 not only serve to provide precise alignment between the first and second components 100, 200, but also serve to provide retention between the first and second components 100, 200 in a self-retaining manner, that is, without the need for additional fasteners, which will be discussed in more detail below.
As illustrated in FIG. 1, an embodiment includes four hollow tubes 104.1, 104.2, 104.3, 104.4 and four mating apertures 204.1, 204.2, 204.3, 204.4. However, it will be appreciated that the scope of the invention is not so limited, and may include any number of hollow tubes 104 with mating apertures 204 consistent with the disclosure herein. When reference is made herein to a hollow tube, a plurality of hollow tubes, or the hollow tubes, reference is made to reference numeral 104, and when reference is made herein to an aperture, a plurality of apertures, or the apertures, reference is made to reference numeral 204.
The elastically deformable hollow tube alignment element 104 is configured and disposed to interferingly, deformably and matingly engage the alignment feature, aperture 204 with tabs 206, in a manner discussed in more detail below, to precisely align and fasten the first component 100 with the second component 200 in two or four directions, such as the +/− x-direction and/or the +/− y-direction of an orthogonal coordinate system, for example, which is herein referred to as two-way or four-way alignment, respectively. Portions of the elastically deformable hollow tube 104 when inserted into the aperture 204 with tabs 206 elastically deform to an elastically averaged final configuration that aligns and retains the first alignment member 102 with the second alignment member 202, and the first component 100 relative to the second component 200, in at least two of four planar orthogonal directions.
For discussion purposes, the mating side of the first alignment member 102 visible in FIG. 1 is labeled 12, and the non-mating side of the second alignment member 202 visible in FIG. 1 is labeled 21. The non-visible sides of the first and second alignment members 102, 202 that are hidden from view in FIG. 1 are herein referred to by reference labels 11 and 22, respectively. For discussion purposes, a plan view of the elastically averaged alignment system 10 as viewed from side 21 of the second component 200 is herein referred to as a front plan view, and a plan view of the elastically averaged alignment system 10 as viewed from side 11 of the first component 100 is herein referred to as a rear plan view.
FIG. 2 depicts a plan view of the first and second components 100, 200 in an assembled state, where the first component 100 is a molded plastic first portion (also herein referred to by reference numeral 100) of a vehicle, and the second component 200 is a stamped sheet metal second portion (also herein referred to by reference numeral 200) of the same vehicle. In an embodiment, the thickness 218 of the second alignment member 202 is thinner than the thickness 114 of the first alignment member 102. In an embodiment, the first portion 100 forms part of a dashboard of the vehicle, and the second portion 200 forms part of a glove box of the vehicle. However, it will be appreciated that the first and second components 100, 200 may form other parts of the vehicle having features consistent with the disclosure herein.
Reference is now made to FIG. 3 in combination with FIG. 1, where FIG. 3 is an expanded perspective view of detail 300 in FIG. 2. Each hollow tube 104 has a central axis 106 that extends perpendicularly outward from the side 12 (also herein referred to as a first surface) of the first component 100, and each tab 206 extends outward relative to the first surface 12 of the first component 100, thereby facilitating engagement of each hollow tube 104 into each respective alignment feature (aperture 204 plus tabs 206) during assembly of the first and second components 100, 200. In an embodiment, the plurality of tabs 206 are bent in a pre-formed shape to extend outward relative to the first surface 12 of the first component 100 in a z-direction defined by the central axis 106 of the hollow tube 104, which is illustrated by bend lines 208 (also illustrated in FIGS. 5 and 6). To form the tabs 206, slots 220 are provided in the second component 200 at least up to the bend line 208. As depicted in the various figures including FIG. 3, the plurality of tabs 206 includes a first pair of opposing tabs 206.1, 206.3, and a second pair of opposing tabs 206.2, 206.4 orthogonally arranged with respect to the first pair of opposing tabs 206.1, 206.3. In an embodiment, the first pair of opposing tabs 206.1, 206.3 are disposed relative to the respective hollow tube 104 in an interfering structural arrangement that causes the elastically deformable hollow tube 104 when inserted into its respective aperture 204 to elastically deform at the regions of interference (see interference 216, FIG. 6), and the second pair of opposing tabs 206.2, 206.4 are disposed relative to the respective hollow tube 104 in a non-interfering structural arrangement (see clearance 212, FIG. 5), which will now be discussed with reference to FIGS. 4-6.
FIG. 4 depicts a front plan view of detail 300 of the first and second components 100, 200 just prior to engagement of the hollow tube 104.1 with its respective aperture 204.1, FIG. 5 depicts a section cut along cut lines 5-5 of FIG. 4, but with the hollow tube 104.1 now fully engaged with its respective aperture 204.1, and FIG. 6 depicts a section cut along cut lines 6-6 of FIG. 4, also with the hollow tube 104.1 now fully engaged with its respective aperture 204.1. As depicted in FIGS. 4 and 5, the outer diameter 108 of the hollow tube 104.1 is smaller than the opening 210 across tabs 206.2 and 206.4 creating a clearance 212 therebetween, and as depicted in FIGS. 4 and 6, the outer diameter 108 of the hollow tube 104.1 is greater than the opening 214 across tabs 206.1 and 206.3 creating an interference 216 therebetween. Where the second component 200 is a stamped sheet metal component, the edges 222 (see FIG. 6) of the stamped tabs 206.1, 206.3 will provide a sharp and relatively stiff edge that will tend to dig into the relatively softer plastic material of the hollow tubes 104 when the first and second components 100, 200 are fully engaged with each other, thereby providing a self-retaining arrangement between the hollow tubes 104 and their respective alignment apertures 204. The upward bend 224 (see FIG. 6) of the tabs 206.1, 206.3 serves to facilitate insertion of the hollow tubes 104 into their respective alignment apertures 204, while deterring separation therebetween.
In an embodiment, and with reference to FIGS. 1, 5 and 6, the first component 100 optionally includes a support 110 disposed proximate the hollow tube 104.1 (FIG. 1 depicts only hollow tube 104.1 having optional supports 110, but it will be appreciated that all of the other hollow tubes 104.2, 104.3, 104.4 may also include optional supports 110), where the support 110 has a support surface 112 disposed in such a manner as to support the second component 200 when the hollow tube 104.1 is interferingly, deformably and matingly inserted into its respective aperture 204.1. While reference is made herein to hollow tube 104.1 and aperture 204.1 in relation to support 110 and support surface 112, it will be appreciated that this is exemplary only, and that any or all of the hollow tubes 104 may include an associated support 110 and support surface 112 for a purpose disclosed herein. Optional supports 110 may be integrally formed with the hollow tubes 104 to increase the stiffness of the lower portion of the hollow tubes 104, or may be separated therefrom to increase the flexibility of the upper and lower portions of the hollow tubes 104.
While FIG. 4 depicts the wider opening 210 oriented parallel with the y-axis and the narrower opening 214 oriented parallel with the x-axis to form an elongated aperture, it will be appreciated that this is merely exemplary of just one of many orientations, and that the elongated aperture may be oriented with the wider opening 210 oriented parallel with the x-axis, or oriented at an angle to both the x and y-axes.
In an embodiment, and with reference back to FIG. 1, the first component 100 includes a first and a second hollow tube 104, such as hollow tubes 104.1, 104.4 or 104.2, 104.3 for example, and the second component 200 includes a first and a second respective aperture 204, such as apertures 204.1, 204.4 or 204.2, 204.3 for example, where the first hollow tube 104.1 is configured and disposed to interferingly, deformably and matingly engage the first aperture 204.1, and the second hollow tube 104.4 is configured and disposed to interferingly, deformably and matingly engage the second aperture 204.4. Where both apertures 204.1 and 204.4 are elongated apertures, as discussed above, having their wider openings 210 oriented in a same direction, such as parallel with the x-axis for example, portions of the first and second hollow tubes 104.1, 104.4 when inserted into respective ones of the first and second apertures 204.1, 204.4 elastically deform to an elastically averaged final configuration that aligns and retains the first alignment member 102 with the second alignment member 202 in two of four planar orthogonal directions, such as with respect to the +/− y-directions for example.
Reference is now made to FIG. 7, which depicts a front plan view of detail 300a, which is similar to detail 300 depicted in FIG. 4, but with opening 214 across tabs 206.1 and 206.3 being equal to opening 214 across orthogonally oriented tabs 206.2a and 206.4a, thereby creating a same degree of interference 216 (see interference 216 in FIG. 6 for example) between the tab edges of aperture 204.1a and the hollow tube 104.1. Accordingly, an embodiment includes an arrangement where a first pair of opposing tabs 206.1, 206.3 and a second pair of opposing tabs 206.2a, 206.4a are respectively disposed relative to the hollow tube 104.1 in an interfering structural arrangement that causes the elastically deformable hollow tube 104.1 when inserted into its respective aperture 204.1a to elastically deform at the regions of interference (at 216), which will be easily recognized with reference to FIG. 6 for both pairs of opposing tabs. When configured as depicted in FIG. 7, aperture 204.1a is herein referred to as a non-elongated aperture.
In an embodiment, and with reference back to FIG. 1 in combination with FIG. 7, the first component 100 may include a first and a second hollow tube 104, such as hollow tubes 104.1, 104.4 or 104.2, 104.3 for example, and the second component 200 may include a first and a second respective aperture 204, such as apertures 204.1a, 204.4a or 204.2a, 204.3a for example and configured as depicted in FIG. 7, where the first hollow tube 104.1 is configured and disposed to interferingly, deformably and matingly engage the first aperture 204.1a, and the second hollow tube 104.4 is configured and disposed to interferingly, deformably and matingly engage the second aperture 204.4a. Where both apertures 204.1a and 204.4a are non-elongated apertures, as discussed above in connection with FIG. 7, such that portions of the first and second hollow tubes 104.1, 104.4 when inserted into respective ones of the first and second apertures 204.1a, 204.4a elastically deform to an elastically averaged final configuration that aligns and retains the first alignment member 102 with the second alignment member 202 in four planar orthogonal directions, such as with respect to the +/− x-directions and the +/− y-directions for example.
While FIGS. 1-7 depict four tabs 206.1, 206.2, 206.3, 206.4 formed in apertures 204, it will be appreciated that the scope of the invention is not limited to just four tabs, and encompasses any number of tabs suitable for a purpose disclosed herein, such as but not limited to six or eight tabs for example.
In view of all that is disclosed and illustrated herein, in combination with other elastic averaging alignment elements and/or apertures as disclosed in commonly owned, co-pending U.S. patent application Ser. No. 13/187,675, now U.S. Publication No. 2013-0019455A1, for example, it will be appreciated that the scope of the invention is not limited to only the use of the herein disclosed elastically averaged alignment system 10 having elastically deformable hollow tubes 104 configured and disposed to interferingly, deformably and matingly engage respective ones of self-retaining alignment apertures 204 having tabs 206, but also encompasses the use of the herein disclosed elastically averaged alignment system 10 in combination with other elastic averaging alignment features, male or female. By using a plurality of various elastically deformable alignment features, added precision in the alignment and self-retention of the first and second components 100, 200 can result.
When the first component 100 and second component 200 are components of a vehicle, an advantageous assembly results because the clamping force, together with the elastic deformation of the alignment features that has these parts in pressing contact already, reduces the tendency of the components to vibrate or rattle against one another, and thus improves the noise, vibration and harshness (NVH) characteristics of the components and the vehicle in which they are installed. The selective engagement of the elastically deformable alignment element (hollow tube 104) and the alignment feature (aperture 204 with tabs 206) also provides a stiffened assembly of the first component 100 and second component 200 when the first and second components are mutually mated to each other, including a stiffness that is greater than that realized by using the alignment features alone, since the clamping force between the first component and second component increases the stiffness of the assembly, for example.
While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention will include all embodiments falling within the scope of the application.

## Claims

1. An elastically averaging self-retaining alignment system, comprising:
a first component comprising a first alignment member and an elastically deformable alignment element fixedly disposed with respect to the first alignment member, the alignment element comprising a hollow tube;
a second component comprising a second alignment member and an alignment feature fixedly disposed with respect to the second alignment member, the alignment feature comprising an aperture comprising a plurality of inwardly extending tabs;
wherein the elastically deformable alignment element is configured and disposed to interferingly, deformably and matingly engage the alignment feature;
wherein portions of the elastically deformable alignment element when inserted into the alignment feature elastically deform to an elastically averaged final configuration that aligns and retains the first component relative to the second component in at least two of four planar orthogonal directions;
wherein the plurality of tabs comprises a first pair of opposing tabs, and a second pair of opposing tabs spaced apart from the first pair of opposing tabs;
wherein the first pair of opposing tabs are disposed relative to the hollow tube in a non-interfering structural arrangement; and
wherein the second pair of opposing tabs are disposed relative to the hollow tube in an interfering structural arrangement that causes the elastically deformable hollow tube when inserted into the aperture to elastically deform at the regions of interference.

2. The elastically averaging self-retaining alignment system of claim 1, wherein:
a central axis of the hollow tube extends perpendicularly outward from a first surface of the first component; and
the plurality of tabs also extend outward relative to the first surface of the first component.

3. The elastically averaging self-retaining alignment system of claim 2, wherein:
the plurality of tabs are bent in a pre-formed shape to extend outward relative to the first surface of the first component in a direction defined by the central axis of the hollow tube.

4. The elastically averaging self-retaining alignment system of claim 1, wherein:
the second pair of opposing tabs are orthogonally arranged with respect to the first pair of opposing tabs.

5. The elastically averaging self-retaining alignment system of claim 4, wherein:
the first pair of opposing tabs and the second pair of opposing tabs are respectively disposed relative to the hollow tube in an interfering structural arrangement that causes the elastically deformable hollow tube when inserted into the aperture to elastically deform at the regions of interference.

6. The elastically averaging self-retaining alignment system of claim 1, wherein the first component further comprises:
a support member disposed proximate the hollow tube and having a support surface disposed to support the second component when the hollow tube is interferingly, deformably and matingly inserted into the aperture.

7. The elastically averaging self-retaining alignment system of claim 1, wherein:
the first component comprises a first and a second of the hollow tube;
the second component comprises a first and a second of the aperture;
the first hollow tube is configured and disposed to interferingly, deformably and matingly engage the first aperture;
the second hollow tube is configured and disposed to interferingly, deformably and matingly engage the second aperture; and
portions of the first and second hollow tubes when inserted into respective ones of the first and second apertures elastically deform to an elastically averaged final configuration that aligns and retains the first component relative to the second component in two of four planar orthogonal directions.

8. The elastically averaging self-retaining alignment system of claim 5, wherein:
the first component comprises a first and a second of the hollow tube;
the second component comprises a first and a second of the aperture;
the first hollow tube is configured and disposed to interferingly, deformably and matingly engage the first aperture;
the second hollow tube is configured and disposed to interferingly, deformably and matingly engage the second aperture; and
portions of the first and second hollow tubes when inserted into respective ones of the first and second apertures elastically deform to an elastically averaged final configuration that aligns and retains the first component relative to the second component in four planar orthogonal directions.

9. The elastically averaging self-retaining alignment system of claim 1, wherein:
the first component comprises a first portion of a vehicle; and
the second component comprises a second portion of the vehicle.

10. The elastically averaging self-retaining alignment system of claim 1, wherein:
the first component is made from injection moldable plastic; and
the second component is made from stamped sheet metal.

11. The elastically averaging self-retaining alignment system of claim 1, wherein:
a thickness of the second component is less than a thickness of the first component.