Systems and methods of forming and removing support structures formed in a powder bed fusion (PBF) system are provided. The support structures are formed with designated failure zones that are designed to fail in a controlled fashion when resonated by one or more resonation devices.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
2.
RADIATION-ENABLED RETENTION FEATURES FOR FIXTURELESS ASSEMBLY OF NODE-BASED STRUCTURES
Retention features are provided for joining at least two structural components in a fixtureless assembly system. A first structure including a groove may be configured to contain at least one adhesive, and a second structure may include a tongue configured to contact the at least one adhesive to join the first and second structures. The first structure may also include at least one window that receives electromagnetic (EM) radiation from an EM radiation source into the groove. The at least one adhesive is configured to cure at a first rate upon exposure to one of time or heating, and the at least one adhesive is configured to cure at a second rate faster than the first rate upon exposure to the EM radiation.
Aspects are provided herein for vehicle structures. The vehicle structures can include a caliper portion configured to apply a braking force, the caliper portion including an inner housing, an outer housing, and a bridge portion, wherein the bridge portion connects the inner housing and the outer housing. In various embodiments, the outer housing can include an inner surface configured to face a rotor, in which the inner surface includes a sweep area configured to allow the rotor to tilt during installation and removal of the rotor. The vehicle structures can further include an upright portion configured to couple to a wheel of a vehicle, the upright portion being connected to the inner housing. Further, the vehicle structure can include a stiffening portion that connects the upright portion to at least the bridge portion or the outer housing. In various embodiments, the vehicle structures can be 3D-printed.
In the present disclosure, systems and apparatuses of a low deflection end-of-arm tooling configured to interface with robots are described. In one aspect, an apparatus may include a shaft with dimensions that include a length greater than a width and having lengthwise distal and proximal ends, and the distal end may be configured to interface with a tool. The apparatus may further includes a flange connected to the proximal end of the shaft and configured to interface with a robotic arm. The apparatus may further include a tool located at the proximal end of the shaft and configured to interface with a plurality of parts associated with vehicular assembly. The shaft may be configured to resist deformation beyond a configured amount when a respective load is applied by each part of the plurality of parts retained by the tool.
An additive manufacturing system comprises an apparatus arranged to distribute layer of metallic powder across a build plane and a power source arranged to emit a beam of energy at the build plane and fuse the metallic powder into a portion of a part. The system includes a processor configured to steer the beam of energy across the build plane and receive data generated by one or more sensors that detect electromagnetic energy emitted from the build plane when the beam of energy fuses the metallic powder. The received data is converted into one or more parameters that indicate one or more conditions at the build plane while the beam of energy fuses the metallic powder. The one or more parameters are used as input into a machine learning algorithm to detect one or more defects in the fused metallic powder.
G01N 21/95 - Investigating the presence of flaws, defects or contamination characterised by the material or shape of the object to be examined
G01N 21/88 - Investigating the presence of flaws, defects or contamination
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B22F 10/366 - Scanning parameters, e.g. hatch distance or scanning strategy
G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
The present disclosure relates to custom additively manufactured core structures and the manufacture thereof In one aspect, a panel for use in a transport structure includes first and second face sheets, and an additively manufactured (AM) core affixed between the first and second face sheets. The AM core is foldable such that at least one portion of the AM core is movable between a folded position and an unfolded position. In another aspect of the disclosure, a method for producing a panel for use in a transport structure includes additively manufacturing a core is disclosed.
B32B 3/12 - Layered products essentially comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products essentially having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material characterised by a layer of regularly-arranged cells whether integral or formed individually or by conjunction of separate strips, e.g. honeycomb structure
B33Y 80/00 - Products made by additive manufacturing
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 3/26 - Layered products essentially comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products essentially having particular features of form characterised by a layer with cavities or internal voids
Apparatus and methods for removing and/or destroying support structures associated with objects fabricated using additive manufacturing techniques are presented herein. Structural supports may be used during an additive manufacturing process to prevent deformation of a build piece (e.g., three dimensional (3D) printed structure). In some examples, a build piece may be manufactured such that the structural supports are internal to the completed build piece. However, removing the structural supports may reduce the weight of the build piece and reduce the amount of debris trapped within the build piece. Thus, certain aspects of the disclosure are directed to a hose including a bendable and elongated tube member as well as a fracturing member configured to fracture an internal support structure within an additively manufactured part.
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
F16L 11/12 - Hoses, i.e. flexible pipes made of rubber or flexible plastics with arrangements for particular purposes, e.g. specially profiled, with protecting layer, heated, electrically conducting
F16L 11/10 - Hoses, i.e. flexible pipes made of rubber or flexible plastics with reinforcements not embedded in the wall
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
8.
ELECTROCOATING (E-COATING) ON A PART BY PART BASIS
The instant disclosure describes example techniques for bonding multiple metal structures prior or subsequent to application of a protective coating (e.g., an electrocoating or e-coating) to the structures. In certain aspects, the structures may include one or more attachment points for attaching a single structure or multiple structures bonded together to a clamp or other suitable means for applying an electrical current to the structure(s).
The present aspects include an adhesive and mechanically bonded adapter or node. The adapter or node comprises a connection member, including: an outer wall extending in a first direction from a first proximal end to a first distal end; an inner wall extending within the outer wall, in the first direction, from a second proximal end to a second distal end; and a base wall extending from an inner surface of the outer wall to an outer surface of the inner wall between the first proximal end and the second proximal end; and wherein the outer wall, the inner wall, and the base wall define a space having a distance between the outer wall and the inner wall that varies in the first direction, wherein the space is configured to fixedly position an end portion of a tube inserted into the space such that the end portion is fixed to the inner surface of the outer wall and the outer surface of the inner wall.
Systems, methods, and computer-readable media for robotic joining of components, parts, and structures are disclosed. A method in accordance with an aspect of the present disclosure comprises determining a target first position and a target second position in a reference frame, controlling robotic arms to move a first part to the target first position and a second part to the target second position, measuring the parts at the target first and second positions to obtain a measured first and second positions, performing a first operation to determine differences between the measured positions and the target positions, and when the differences exceeds desired tolerances, controlling the robotic arms to move the parts to compensate for the differences, and controlling at least the first or second robotic arm to join the first and second parts after the first and second operations are concluded.
The present aspects include an assembly having discretized and segmented joint architecture. The assembly comprises a first structure including an outer wall and an inner wall, wherein the outer wall and the inner wall extend from a base of the first structure, and define a groove, and a plurality of connecting walls extending between the outer wall and the inner wall such that the groove is divided into a plurality of groove segments defined by the outer wall, the inner wall, and the plurality of connecting walls. The assembly further comprises a second structure including a plurality of tongue segments which extend into the plurality of groove segments. A first adhesive is inserted into the groove, thereby bonding the plurality of tongue segments within the plurality of groove segments such that the first and second structures are fixed together.
Alloyed metals, and techniques for creating parts from alloyed metals, are disclosed. An apparatus in accordance with an aspect of the present disclosure comprises an alloy. Such an alloy comprises aluminum (Al), magnesium (Mg), and titanium (Ti), wherein a structure of the alloy has an elastic modulus of at least 68 gigapascals (GPa).
Techniques for structurally integrated heat exchangers are presented herein. A heat exchanger in accordance with an aspect of the present disclosure comprises a structure configured to enclose a volume for storing a first fluid, and to connect to a load. The heat exchanger further comprises a first and a second header first arranged in opposing inner walls of the structure. The heat exchanger further comprises one or more load-bearing struts extending to connect the first and second headers within the volume and configured to pass a second fluid through the volume for transferring heat to the first fluid, the second fluid configured to cool a different component in the vehicle.
B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 80/00 - Products made by additive manufacturing
F28F 1/02 - Tubular elements of cross-section which is non-circular
B21D 53/06 - Making other particular articles heat exchangers, e.g. radiators, condensers of metal tubes
F28D 1/053 - Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or mo with the heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight
14.
Defect detection for additive manufacturing systems
This invention teaches a quality assurance system for additive manufacturing. This invention teaches a multi-sensor, real-time quality system including sensors, affiliated hardware, and data processing algorithms that are Lagrangian-Eulerian with respect to the reference frames of its associated input measurements. The quality system for Additive Manufacturing is capable of measuring true in-process state variables associated with an additive manufacturing process, i.e., those in-process variables that define a feasible process space within which the process is deemed nominal. The in-process state variables can also be correlated to the part structure or microstructure and can then be useful in identifying particular locations within the part likely to include defects.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 12/44 - Radiation means characterised by the configuration of the radiation means
Aspects for implementing 3-D printed metrology feature geometries and detection are disclosed. The apparatus may a measurement device for a 3-D printed component. The component may include a plurality of printed-in metrology features arranged at different feature locations on a surface of the component. The measurement device can be configured to detect the feature locations of the printed-in metrology features and to determine a position or an orientation of the component based on the detected feature locations. In various embodiments, the metrology feature may be a protruding or recessed spherical portion, with the corresponding feature location at the center of the sphere.
An approach to positioning one or more robotic arms in an assembly system may be described herein. For example, a system for robotic assembly may include a first robot, a second robot, and a control unit. The control unit may be configured to receive a first target location proximal to a second target location. The locations may indicate where the robots are to position the features. The control unit may be configured to calculate a first calculated location of the first feature of the first subcomponent, measure a first measured location of the first feature of the first subcomponent, determine a first transformation matrix between the first calculated location and the first measured location, reposition the first feature of the first subcomponent to the first target location using the first robot, the repositioning based on the first transformation matrix.
Integrated vehicle structures are provided herein. An integrated vehicle structure can include an enclosure portion configured to house an electric motor and a plurality of extended portions extending from the enclosure portion. The enclosure portion and the plurality of extended portions can be load-bearing and configured to bear vehicle loads. The extended portions of the integrated vehicle structures can include a connection portion configured to connect with another load-bearing structure to at least receive or transmit loads. The plurality of extended portions can be configured to transfer vehicle loads along physically separate paths. A portion of the enclosure portion can define an opening configured to allow a drive shaft to connect the electric motor to a wheel. The enclosure portion can be configured with an opening for allowing the installation and removal of the electric motor.
B62D 21/09 - Means for mounting load bearing surfaces
B62D 21/15 - Understructures, i.e. chassis frame on which a vehicle body may be mounted having impact absorbing means, e.g. a frame designed to permanently or temporarily change shape or dimension upon impact with another body
B62D 21/18 - Understructures, i.e. chassis frame on which a vehicle body may be mounted characterised by the vehicle type and not provided for in groups
B60K 1/00 - Arrangement or mounting of electrical propulsion units
18.
METHODS AND SYSTEMS FOR QUALITY INFERENCE AND CONTROL FOR ADDITIVE MANUFACTURING PROCESSES
This disclosure describes an additive manufacturing method that includes monitoring a temperature of a portion of a build plane during an additive manufacturing operation using a temperature sensor as a heat source passes through the portion of the build plane; detecting a peak temperature associated with one or more passes of the heat source through the portion of the build plane; determining a threshold temperature by reducing the peak temperature by a predetermined amount; identifying a time interval during which the monitored temperature exceeds the threshold temperature; identifying, using the time interval, a change in manufacturing conditions likely to result in a manufacturing defect; and changing a process parameter of the heat source in response to the change in manufacturing conditions.
B23K 31/12 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to investigating the properties, e.g. the weldability, of materials
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 12/90 - Means for process control, e.g. cameras or sensors
B22F 10/366 - Scanning parameters, e.g. hatch distance or scanning strategy
B22F 10/368 - Temperature or temperature gradient, e.g. temperature of the melt pool
This invention teaches a multi-sensor quality inference system for additive manufacturing. This invention still further teaches a quality system that is capable of discerning and addressing three quality issues: i) process anomalies, or extreme unpredictable events uncorrelated to process inputs; ii) process variations, or difference between desired process parameters and actual operating conditions; and iii) material structure and properties, or the quality of the resultant material created by the Additive Manufacturing process. This invention further teaches experimental observations of the Additive Manufacturing process made only in a Lagrangian frame of reference. This invention even further teaches the use of the gathered sensor data to evaluate and control additive manufacturing operations in real time.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 10/31 - Calibration of process steps or apparatus settings, e.g. before or during manufacturing
B22F 10/36 - Process control of energy beam parameters
B22F 10/368 - Temperature or temperature gradient, e.g. temperature of the melt pool
B22F 12/90 - Means for process control, e.g. cameras or sensors
B29C 64/386 - Data acquisition or data processing for additive manufacturing
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
G05B 19/418 - Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control (DNC), flexible manufacturing systems (FMS), integrated manufacturing systems (IMS), computer integrated manufacturing (CIM)
One aspect is an apparatus including a plurality of additively manufactured components each having an adhesive injection channel. The components are connected together such that adhesive injection channels are aligned to form an adhesive path that allows adhesive flow between the components. Another aspect is an apparatus, including an additively manufactured component having an adhesive injection channel and an adhesive flow mechanism comprising at least one of an adhesive side end effector or a vacuum side end effector, the adhesive flow mechanism configured to provide adhesive to the adhesive injection channels.
B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
B33Y 80/00 - Products made by additive manufacturing
B62D 27/02 - Connections between superstructure sub-units rigid
B62D 65/02 - Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
C09J 5/00 - Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
Methods and apparatuses for wide-spectrum consumption of output of atomization processes across multi-process and multi-scale additive manufacturing modalities
Methods and apparatuses for identifying an additive manufacturing process for unused output material of an atomization process are described. The method comprises determining a set of characteristics of output material that is unused in a first additive manufacturing process. The method further comprises determining a respective set of parameters associated with respective input material of each of a set of other additive manufacturing processes. The method of further comprises identifying one of the set of other additive manufacturing processes that accepts the output material as input material based on the characteristics of the output material and based on respective sets of parameters.
B22F 10/85 - Data acquisition or data processing for controlling or regulating additive manufacturing processes
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 10/34 - Process control of powder characteristics, e.g. density, oxidation or flowability
B22F 12/82 - Combination of additive manufacturing apparatus or devices with other processing apparatus or devices
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
Methods for joining components, and apparatuses comprising components to be joined, are described. An apparatus in accordance with an aspect of the present disclosure comprises a first component comprising a first feature having a first surface profile, and an additively-manufactured second component comprising a second feature having a second surface profile, wherein the second surface profile is generated at least in part from the first surface profile of the first interface, such that the first surface profile is configured to mate with the second surface profile.
Methods for repurposing waste materials, such as aluminum powder, are disclosed. A method in accordance with an aspect of the present disclosure may comprise collecting a material in a container, the material comprising oxidized aluminum powder, processing the material, which includes heating the material to melt at least a portion of the oxidized aluminum powder, and forming the processed material into at least one component.
B33Y 99/00 - Subject matter not provided for in other groups of this subclass
B22F 3/24 - After-treatment of workpieces or articles
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
24.
AL-MG-SI BASED NEAR-EUTECTIC ALLOY COMPOSITION FOR HIGH STRENGTH AND STIFFNESS APPLICATIONS
Alloy materials and three-dimensional (3-D) printed alloys are disclosed. An alloy in accordance with an aspect of the present disclosure comprises aluminum, magnesium, and silicon wherein a composition of the alloy comprises from at least 5 percent (%) by weight to 20% by weight of silicon and from at least 7% by weight to 10% by weight of magnesium.
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B22F 12/41 - Radiation means characterised by the type, e.g. laser or electron beam
In the present disclosure, methods, systems, and apparatuses for in-process assembly error correction are described. In various embodiments, a target arrangement of parts of an assembly may be obtained, with the target arrangement including a first target position of a first part, a second target position of a second part, and a third target position of a third part. The first part and the second part may be robotically joined based on the first target position and the second target position to obtain a first subassembly of the assembly, with the first subassembly having a first physical arrangement that includes the physical arrangement of the first and second parts after joining. The first physical arrangement may be fitted to the target arrangement to obtain a fitted first physical arrangement. The first subassembly and the third part may be robotically joined based on the fitted first physical arrangement.
This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensor; determining an area of the build plane traversed during the scans; determining a thermal energy density for the area of the build plane traversed by the scans based upon the amount of energy radiated and the area of the build plane traversed by the scans; mapping the thermal energy density to one or more location of the build plane; determining that the thermal energy density is characterized by a density outside a range of density values; and thereafter, adjusting subsequent scans of the energy source across or proximate the one or more locations of the build plane.
B23K 31/12 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to investigating the properties, e.g. the weldability, of materials
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
In some aspects, the additive manufacturing system may access, by a processor of an additive manufacturing system, a machine learning model that is trained to identify defects within a build plane. Also, the additive manufacturing system may capture, by an imaging system of the additive manufacturing system, an image of a build plane of the additive manufacturing system. The build plane can contain an object being manufactured through an additive manufacturing process. In addition, the additive manufacturing system may provide, by the processor, the captured image as an input to the machine learning model. Moreover, the additive manufacturing system may receive, by the processor, an output from the machine learning model identifying a defect in the build plane.
Systems and methods for curing adhesives in a robotic assembly cell are disclosed. An apparatus in accordance with an aspect of the present disclosure comprises a chassis, a gearbox, coupled to the chassis, and a radiation head, coupled to the gearbox, the radiation head emitting radiation in a direction, wherein the radiation head is moveable with respect to the chassis.
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B22F 12/41 - Radiation means characterised by the type, e.g. laser or electron beam
B22F 12/48 - Radiation means with translatory movement in height, e.g. perpendicular to the deposition plane
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 80/00 - Products made by additive manufacturing
Various aspects of robotic grippers are disclosed herein. In one aspect, a robotic gripper may include three gripper fingers arranged on a mechanical end effector, the three gripper fingers configured to translate radially when actuated to contact and align with a gripper interface located on a part to enable manipulation of the part. In various embodiments, each gripper finger may include an elongated portion configured to contact an outer surface of the gripper interface when the gripper fingers are actuated. Each gripper finger may further include a hook portion configured to contact an inner surface of the gripper interface opposing the outer surface. In various embodiments, the hook portion may include a receptacle positioned to align with a complementary protrusion on the gripper interface.
The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component.
B32B 3/12 - Layered products essentially comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products essentially having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material characterised by a layer of regularly-arranged cells whether integral or formed individually or by conjunction of separate strips, e.g. honeycomb structure
B33Y 80/00 - Products made by additive manufacturing
B33Y 50/00 - Data acquisition or data processing for additive manufacturing
B29C 64/386 - Data acquisition or data processing for additive manufacturing
B32B 3/26 - Layered products essentially comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products essentially having particular features of form characterised by a layer with cavities or internal voids
A parts table may comprise a structure including a first surface, a base including a platform affixed to the structure, and kinematic couplers secured to the base and configured to dock with complementary kinematic couplers of an alignment structure, the alignment structure being secured to a floor of an assembly cell, the first surface including a parts interface configured to hold a plurality of parts for assembly in the assembly cell, such that each part of the plurality of parts can be picked up by a robot of the assembly cell when the parts table is docked with the alignment structure, and the parts table is movable to a new location when the kinematic couplers are undocked from the alignment structure.
B25H 1/04 - Work benches; Portable stands or supports for positioning portable tools or work to be operated on thereby of table type portable
B25H 1/10 - Work benches; Portable stands or supports for positioning portable tools or work to be operated on thereby with provision for adjusting holders for tool or work
Methods and apparatuses for calibrating an end effector feature for robotic assembly are disclosed. A method in accordance with an aspect of the present disclosure may comprise obtaining a first set of images of an effector feature coupled to an engagement feature of a robot, the first set of images including at least a first image of the effector feature from a first perspective and a second image of the effector feature from a second perspective, detecting an edge in each of the first image and the second image, determining a coordinate position of the effector feature in a first coordinate system based on the edge of the first image and the edge of the second image, and calibrating the robot based on the coordinate position of the effector feature in the first coordinate system.
Techniques for flexible, on-site additive manufacturing of components or portions thereof for transport structures are disclosed. An automated assembly system for a transport structure may include a plurality of automated constructors to assemble the transport structure. In one aspect, the assembly system may span the full vertically integrated production process, from powder production to recycling. At least some of the automated constructors are able to move in an automated fashion between the station under the guidance of a control system. A first of the automated constructors may include a 3-D printer to print at least a portion of a component and to transfer the component to a second one of the automated constructors for installation during the assembly of the transport structure. The automated constructors may also be adapted to perform a variety of different tasks utilizing sensors for enabling machine-learning.
B29C 64/379 - Handling of additively manufactured objects, e.g. using robots
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
G05B 19/418 - Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control (DNC), flexible manufacturing systems (FMS), integrated manufacturing systems (IMS), computer integrated manufacturing (CIM)
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B29C 70/20 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in a single direction, e.g. roving or other parallel fibres
35.
REMOVAL OF SUPPORTS, AND OTHER MATERIALS FROM SURFACE, AND WITHIN HOLLOW 3D PRINTED PARTS
Methods for removing support structures in additively manufactured parts are disclosed. A method in accordance with an aspect of the present disclosure comprises inserting a demolition object in a first state into a hollow portion of a 3-D printed part, breaking a support structure within the hollow portion by contact with the demolition object, changing the demolition object into a second state while the demolition object is within the hollow portion of the 3-D printed part, and removing the demolition object from the hollow portion of the 3-D printed part.
Methods and apparatuses for using a structure as a sensor are disclosed. An apparatus in accordance with an aspect of the present disclosure comprises an additively-manufactured component comprising a channel, a sensor including an connection point, wherein the sensor is arranged in the channel, and an adhesive arranged in the channel, the adhesive coupling the additively-manufactured component to the sensor, such that the connection point is accessible external to the adhesive, the sensor being configured to provide a signal at the connection point, wherein the signal provides information of an applied force on the additively-manufactured component.
G01L 1/22 - Measuring force or stress, in general by making use of electrokinetic cells, i.e. liquid-containing cells wherein an electrical potential is produced or varied upon the application of stress using resistance strain gauges
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B33Y 80/00 - Products made by additive manufacturing
37.
APPARATUS AND METHODS FOR CALIBRATING ON-AXIS TEMPERATURE SENSORS FOR ADDITIVE MANUFACTURING SYSTEMS
This disclosure describes various methods and apparatus for calibration of temperature sensors in additive manufacturing systems. A method for calibration of temperature sensors can include selecting a first wavelength and a second wavelength spaced apart from the first wavelength; measuring an amount of energy radiated from a black body source at the first wavelength; measuring an amount of energy radiated from the black body source at the second wavelength; generating a relationship between a ratio of the amount of energy radiated at the first wavelength to the amount of energy radiated at the second wavelength; and determining, using the relationship, variations in a temperature of a build plane of an additive manufacturing system based upon a ratio of energy radiated at the first wavelength to energy radiated at the second wavelength.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
38.
SYSTEMS AND METHODS FOR MEASURING RADIATED THERMAL ENERGY DURING AN ADDITIVE MANUFACTURING OPERATION
This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensing system that monitors two discrete wavelengths associated with a blackbody radiation curve of the layer of powder; determining temperature variations for an area of the build plane traversed by the scans based upon a ratio of sensor readings taken at the two discrete wavelengths; determining that the temperature variations are outside a threshold range of values; and thereafter, adjusting subsequent scans of the energy source across or proximate the area of the build plane.
B23K 26/03 - Observing, e.g. monitoring, the workpiece
B23K 26/082 - Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B23K 31/12 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to investigating the properties, e.g. the weldability, of materials
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
39.
VARIABLE BEAM GEOMETRY ENERGY BEAM-BASED POWDER BED FUSION
Apparatuses for additive manufacturing producing an annular beam are disclosed herein. An apparatus in accordance with an aspect of the present disclosure comprises an energy beam source configured to generate an energy beam and a beam shaping applicator configured to shape the energy beam into a geometry and apply the shaped energy beam to an additive manufacturing material, wherein the geometry includes a two-dimensional shape with a perimeter and a hole in the two-dimensional shape within the perimeter.
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
B22F 12/41 - Radiation means characterised by the type, e.g. laser or electron beam
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 10/36 - Process control of energy beam parameters
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
Systems and methods for rotational additive manufacturing are disclosed. An apparatus in accordance with an aspect of the present disclosure comprises a build floor, a depositor system configured to deposit a layer of powder onto the build floor, a motor system causing a rotational motion between the depositor system and the build floor, wherein the depositor system deposits the layer of powder during the rotational motion, a receptacle wall configured to contain the powder on the build floor, an energy beam source configured to apply an energy beam in an active area of the layer of powder to selectively fuse a portion of the powder in the active area to form a portion of a build piece and a gas flow system configured to provide a gas flow across the active area while the energy beam selectively fuses the portion of the layer of powder in the active area.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
Aspects are provided for additively manufacturing a component with reduced surface roughness based on direct energy deposition (DED). A DED apparatus for additively manufacturing a component includes a material supply, one or more deposition heads coupled to the material supply to deposit feedstock from the material supply, and an energy source configured to heat the feedstock as the feedstock is being deposited by the one or more deposition heads. The energy source is configured to reheat one or more portions of a surface of the component to reduce surface roughness as the component is being additively manufactured. The one or more deposition heads may also comprise a plurality of deposition heads which are sized to deposit the feedstock from the material supply at different resolutions to form a surface of the component with reduced surface roughness as the component is being additively manufactured. Thus, structural integrity may be improved.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
42.
BUS BARS FOR PRINTED STRUCTURAL ELECTRIC BATTERY MODULES
Techniques for co-printing of bus bars for printed structural energy modules are presented herein. An apparatus in accordance with an aspect of the present disclosure comprises a first component configured to be a primary structure of a vehicle, the first component-co-printed with a first electrical conductive path, the first electrical conductive path configured to be connected to a second electrical conductive path of a second component of the vehicle, wherein the first electrical conductive path and the second electrical conductive path are configured to enable electricity transmission.
H02B 1/20 - Bus-bar or other wiring layouts, e.g. in cubicles, in switchyards
H01M 50/505 - Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing comprising a single busbar
B33Y 80/00 - Products made by additive manufacturing
Methods and apparatuses for energy unit cells for primary structures are described. The method comprises obtaining enclosure criteria of an enclosure space, wherein the enclosure space is configured to contain an energy storage device. The method further comprises obtaining a load case of a primary structure of a vehicle. The method further comprises determining a primary structure design based on the enclosure criteria and the load case, where the primary structure design incorporates the enclosure space.
B60L 50/60 - Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
Alloy materials and three-dimensional (3-D) printed alloys are disclosed. An alloy in accordance with an aspect of the present disclosure comprises cobalt, titanium, silicon, magnesium, zinc, manganese, zirconium, and aluminum, wherein a structure of the alloy as printed by a 3D printing process has a yield strength of at least 300 Megapascals and an elongation of at least 4 percent.
C22C 21/02 - Alloys based on aluminium with silicon as the next major constituent
C22F 1/043 - Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B33Y 70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
A virtual railroad of vehicles is disclosed. In one aspect of the disclosure, a system includes one or more passenger vehicles of a peloton, and a first engine vehicle of the peloton. The first engine vehicle communicatively connected to the one or more passenger vehicles, wherein the first engine vehicle comprises: a processor communicatively connected to a memory and is configured to receive status information of the one or more passenger vehicles, determine, based on the received status information, a set of current values for a set of vehicle attributes for each of the one or more passenger vehicles, and adjust, based on the set of current values for the set of vehicle attributes, a position of a corresponding passenger vehicle of the one or more passenger vehicles.
B60W 30/16 - Control of distance between vehicles, e.g. keeping a distance to preceding vehicle
B60W 30/165 - Control of distance between vehicles, e.g. keeping a distance to preceding vehicle automatically following the path of a preceding lead vehicle, e.g. "electronic tow-bar"
H04W 4/44 - Services specially adapted for particular environments, situations or purposes for vehicles, e.g. vehicle-to-pedestrians [V2P] for communication between vehicles and infrastructures, e.g. vehicle-to-cloud [V2C] or vehicle-to-home [V2H]
46.
Multi-component structure optimization for combining 3-D printed and commercially available parts
Aspects of methods, apparatuses, and computer-readable media for performing multi-material selection optimization (MMSO) to provide topologically and geometrically optimized multi-component structures (MCSs) across a plurality of design inputs and constraints are proposed. In some embodiments, a 3-D print model of an object based on load case criteria is obtained. A portion of the 3-D print model is determined that can be replaced with a commercial-off-the-shelf (COTS) part model such that the load case criteria remain satisfied. The portion or the 3-D print model can then be replaced with the COTS part model to determine the MCS model. In various embodiments, a mesh representation of the model can be generated, and plurality of optimization techniques can be used to determine the MCS model.
Techniques for joining nodes and subcomponents are presented herein. An apparatus in accordance with an aspect of the present disclosure comprises a 3-D printed first part having an interconnect co-printed with the first part such that the interconnect of the first part can float within the first part, and a 3-D printed second part having an interconnect co-printed with the second part such that the interconnect of the second part can float within the second part, wherein the interconnects of the first and second parts are configured to form a connection between the first and second parts.
An autonomous delivery vehicle (ADV) may include multiple storage compartments, and each storage compartment of the plurality of storage compartments has a respective storage space and is associated with a respective delivery location. The respective storage space of each storage compartment may store one or more items. Each storage compartment may transition from a first state to a second state, and the first state may prevent access to the storage space of the respective storage compartment and the second state may enable access to the respective storage space of the respective storage compartment. The ADV may further include a receiver configured to receive first information from a computing system remote and external to the first ADV, and the first ADV may autonomously travel to one or more locations based on the first information.
Techniques for rapid powder removal in a 3-D printer are disclosed. In various embodiments, the 3-D printer has a build plate for supporting a build piece. The build plate includes first structures for supporting unfused powder on a top of the build plate when the first structures are in a closed configuration. The first structures can transition to an open configuration to expose paths for allowing the unfused powder to pass through the build plate, and a second structure for preventing the build piece from passing through the build plate when the first structures are in the open configuration. In various embodiments, the unfused powder can thereafter be replaced with cool powder to assist in forming a predictable microstructure that makes up the build piece.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
Aspects are provided for additively manufacturing a component based on direct energy deposition (DED). An apparatus may include a DED system configured to additively manufacture a part. The apparatus may further include a forging tool configured to forge a region of the part during the additive manufacturing. In various embodiments, a solid body is used opposite to the forging tool during the forgery. For example, the solid body may include a mandrel against which the region of the part is forged.
Methods and apparatuses for assembling components are described. An apparatus in accordance with an aspect of the present disclosure comprises a first structure having a first tongue, a second tongue, and a third tongue, the second tongue being between the first tongue and the third tongue, a second structure having a first groove, a second groove, and a third groove, the second groove being between the first groove and the third groove, a first adhesive, coupled to the first tongue and the first groove and coupled to the third tongue and the third groove when the first structure is coupled to the second structure, and a second adhesive coupled to the second tongue and the second groove when the first structure is coupled to the second structure, wherein the first adhesive is injected into the first groove and the third groove and the second adhesive is injected into the second groove.
Methods and apparatuses for disassembling components are described. An apparatus in accordance with an aspect of the present disclosure comprises a first component including a first adhesive interface, a second component including a second adhesive interface, a joint between the first and second adhesive interfaces, the joint comprising an adhesive bonding to the first adhesive interface and to the second adhesive interface, such that the first component and the second component are joined together, and at least one thermal element in the adhesive, wherein the at least one thermal element is configured to weaken the joint by heating the adhesive when an energy is applied to the thermal element.
B22F 10/64 - Treatment of workpieces or articles after build-up by thermal means
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 10/62 - Treatment of workpieces or articles after build-up by chemical means
B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
B33Y 80/00 - Products made by additive manufacturing
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
Alloyed metals, and techniques for creating parts from alloyed metals, are disclosed. An apparatus in accordance with an aspect of the present disclosure comprises an alloy. Such an alloy comprises magnesium (Mg), zirconium (Zr), manganese (Mn), and aluminum (Al), wherein inclusion of the Mg, the Zr, and the Mn produce a structure of the alloy, the structure having a yield strength of at least 80 Megapascals (MPa) and having an elongation of at least 10 percent (%).
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 70/00 - Materials specially adapted for additive manufacturing
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
54.
SYSTEMS AND METHODS FOR JOINING NODES AND OTHER STRUCTURES
An additively manufactured node is disclosed. A node is an additively manufactured (AM) structure that includes a feature, e.g., a socket, a channel, etc., for accepting another structure, e.g., a tube, a panel, etc. The node can include a node surface of a receptacle extending into the node. The receptacle can receive a structure, and a seal interface on the node surface can seat a seal member between the node surface and the structure to create an adhesive region between the node and the structure, the adhesive region being bounded by the node surface, the structure, and the seal member. The node can also include two channels connecting an exterior surface of the node to the adhesive region. In this way, adhesive can be injected into the adhesive region between the node and the structure, and the adhesive can be contained by the seal member.
Apparatuses and methods are provided for joining at least two structural components. A receiving structure including a mating profile having one or more tongues and grooves may be configured to contain at least one adhesive. A joint feature of a node structure may include a mating feature with a converging profile configured to mate with the mating profile of the receiving structure. One or more tongues and grooves may be present at the joint feature and configured to mate with corresponding tongues and grooves of the receiving structure.
Integration of drive elements with an unsprung structure is disclosed. In one aspect of the disclosure, a motor includes a stator configured to mount to an unsprung structure of a wheeled vehicle through at least a damper or a spring. The motor further includes a rotor configured to drive a wheel of the vehicle.
Techniques for optimizing powder hole removal are disclosed. In one aspect, an apparatus for inserting powder removal features may identify what powder removal features are optimal for a given AM component, as well as the optimal location and physical characteristics of these features. The features are automatedly added to the component, and an FEA test is run. In the event of failure, the offending feature is removed and the process is repeated. If successful then the loose powder may be removed in a post-processing step following AM.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B23K 26/142 - Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor for the removal of by-products
B23K 26/14 - Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
B22F 3/24 - After-treatment of workpieces or articles
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B33Y 50/00 - Data acquisition or data processing for additive manufacturing
One aspect is an apparatus including a first node including a first bonding surface and a second node including a second bonding surface. The apparatus includes a feature configured to accept an adhesive and an adhesive channel coupled to the feature configured to accept the adhesive. The apparatus includes a shear joint coupling the first node and the second node, the shear joint configured to receive the adhesive in an adhesive region formed by the first bonding surface and the second bonding surface, the adhesive for coupling the first bonding surface to the second bonding surface through the feature configured to accept the adhesive.
A resin composition can includes a first isocyanurate component and a first bonding component bonded to the first isocyanurate component. The first bonding component can be configured to bond to a second bonding component that is bonded to a second isocyanurate component. The first bonding component can be configured to bond to the second bonding component based upon an application of an initiator to the resin composition. In this way, the first isocyanurate component can be coupled to the second isocyanurate component. The resin composition can be either in a pre-cured state in which the first isocyanurate component is not coupled to the second isocyanurate component or in a post-cured state in which at least a portion of the first isocyanurate component is coupled to at least a portion of the second isocyanurate component.
This disclosure describes an additive manufacturing system that includes a build plane having a first region and a second region. Multiple energy source can be positioned above the build plane and configured to direct energy into the first and second regions of the build plane. The system includes optical sensors configured to monitor an intensity of light emitted from the energy sources. A processor associated with the additive manufacturing system is configured to adjust the sensor outputs in response to the energy sources coming into close proximity.
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B23K 26/082 - Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B23K 26/03 - Observing, e.g. monitoring, the workpiece
An apparatus for assembling structures is provided. The apparatus includes an assembly robot and a mobile unit coupled to or integrated with the assembly robot. A controller coupled to the assembly robot and the mobile unit can selectively operate the assembly robot and the mobile unit based at least in part on an assembly being produced, such that the controller selectively operates the mobile unit when at least one of the assembly being produced and a sequence of assembly of is altered.
B23P 21/00 - Machines for assembling a multiplicity of different parts to compose units, with or without preceding or subsequent working of such parts, e.g. with programme control
62.
VARIABLE BEAM GEOMETRY LASER-BASED POWDER BED FUSION
Systems and methods of adapting the geometrical shape of a laser beam in laser-based powder-bed fusion (PBF) are provided. An apparatus for laser-based powder-bed fusion includes a depositor that deposits a plurality of layers of a powder material. The apparatus further includes a laser beam source that generates a laser beam having a variable beam geometry. A laser application component applies the laser beam in one of a plurality of beam geometries to fuse the powder material to construct a build piece.
In various aspects, 3D printers and recoaters incorporate sensor systems coupled to or integrated with the 3D printers. The sensor systems may include eddy current sensors and other sensors configured to measure an electromagnetic characteristic of the build piece. A three-dimensional (3-D) printer in one aspect includes a depositor configured to deposit metal, an energy beam source configured to selectively melt the metal to form a portion of a build piece, and a sensor configured to move relative to a surface of the print area and to measure an electromagnetic characteristic of the portion of the print area. The measured data can be used to detect defects and other information about the build piece that can be used to fix the defects or enhance the build piece geometry during the printing.
B22F 12/90 - Means for process control, e.g. cameras or sensors
G01N 27/90 - Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents
B23K 26/03 - Observing, e.g. monitoring, the workpiece
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/00 - Data acquisition or data processing for additive manufacturing
B22F 12/50 - Means for feeding of material, e.g. heads
64.
METHODS AND APPARATUSES FOR BALL MILLING TO PRODUCE POWDER FOR ADDITIVE MANUFACTURING
Methods and apparatuses for producing spherical metallic powders through continuous ball milling are described. The apparatus comprises a comminution component including an inlet to receive a metallic material at a first region within the comminution component and an outlet to dispense the metallic powder from a second region within the comminution component. The apparatus further comprises a plurality of grinding components to grind the metallic material, the plurality of grinding components being arranged within the comminution component. The apparatus comprises a drive component, connected with the comminution component, to induce movement of the metallic material and the plurality of grinding components within the comminution component such that the metallic material is fragmented through contact with the plurality of grinding components at the first region and an external surface of the fragmented metallic material is altered at the second region to produce the metallic powder.
B02C 17/16 - Mills in which a fixed container houses stirring means tumbling the charge
B22F 9/04 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from solid material, e.g. by crushing, grinding or milling
B02C 17/18 - Disintegrating by tumbling mills, i.e. mills having a container charged with the material to be disintegrated with or without special disintegrating members such as pebbles or balls - Details
B02C 17/10 - Disintegrating by tumbling mills, i.e. mills having a container charged with the material to be disintegrated with or without special disintegrating members such as pebbles or balls with one or a few disintegrating members arranged in the container
An additively manufactured node is disclosed. A node is an additively manufactured (AM) structure that includes a feature, e.g., a socket, a channel, etc., for accepting another structure, e.g., a tube, a panel, etc. The node can include a node surface of a receptacle extending into the node. The receptacle can receive a structure, and a seal interface on the node surface can seat a seal member between the node surface and the structure to create an adhesive region between the node and the structure, the adhesive region being bounded by the node surface, the structure, and the seal member. The node can also include two channels connecting an exterior surface of the node to the adhesive region. In this way, adhesive can be injected into the adhesive region between the node and the structure, and the adhesive can be contained by the seal member.
Having a flexible robotic system layout that allows for the assembly of any structure creates a challenge in finding an optimal sequence of assembly. In some examples, the optimal sequence of assembly may provide the highest robot utilization, the shortest cycle time, the greatest assembly accuracy of the final assembly, or any combination thereof. The processing system disclosed herein may be configured to generate assembly sequences for a plurality of parts and determine an optimal assembly sequence from the generated assembly sequences by comparing the generated assembly sequences.
G05B 19/418 - Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control (DNC), flexible manufacturing systems (FMS), integrated manufacturing systems (IMS), computer integrated manufacturing (CIM)
Adaptable manufacturing systems, methods, and apparatuses are disclosed. An apparatus for manufacturing a product in accordance with the present disclosure may include a design apparatus, an assembly apparatus, and a control apparatus, coupled to the design apparatus and the assembly apparatus. The control apparatus receives input information from the design apparatus and the assembly apparatus. The control apparatus provides output information for altering at least one parameter used by at least one of the design apparatus and the assembly apparatus in the manufacture of the product.
G05B 19/418 - Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control (DNC), flexible manufacturing systems (FMS), integrated manufacturing systems (IMS), computer integrated manufacturing (CIM)
68.
Mechanical part retention features for additively manufactured structures
Part retention features are disclosed for securing additively manufactured (AM) parts or for securing an AM part with another component, such as a node, panel, tube, extrusion, and the like, while an adhesive is being applied and/or while the adhesive is undergoing expansion due to a subsequent curing process. The retention features described herein can be used in the context of one or more AM parts such that the elements used to house the retention features (e.g., grooves, apertures, elastic elements, etc.) can advantageously be co-printed with the AM part, thereby removing a manufacturing step. The retention features also can be made with flatter profiles than existing solutions, making the overall structure smaller and less cumbersome to assemble.
A node to panel interface structure for use in a transport structure such as a vehicle is disclosed. In an aspect, the node includes a base, first and second sides protruding from the base to form a recess for receiving a panel, ports for adhesive injection and/or vacuum generation, one or more adhesive regions disposed on a surface of each side adjacent the panel, and at least one channel coupled between the first and second ports and configured to fill the adhesive regions with an adhesive, the adhesive being cured to form a node-panel interface. The node may be additively manufactured. In an exemplary embodiment, the node may use sealant features for including sealants that border and define the adhesive regions, and that may hermetically seal the region before and after adhesive injection. In another embodiment, the node may include isolation features for including isolators for inhibiting galvanic corrosion. In another aspect, adhesive may be filled serially on the adhesive regions on the first side and then on the adhesive regions on the second side. Adhesive may alternatively may be filled in parallel, or concurrently, on the adhesive regions of both sides.
An additive manufacturing system comprises an apparatus arranged to distribute layer of metallic powder across a build plane and a power source arranged to emit a beam of energy at the build plane and fuse the metallic powder into a portion of a part. The system includes a processor configured to steer the beam of energy across the build plane and receive data generated by one or more sensors that detect electromagnetic energy emitted from the build plane when the beam of energy fuses the metallic powder. The received data is converted into one or more parameters that indicate one or more conditions at the build plane while the beam of energy fuses the metallic powder. The one or more parameters are used as input into a machine learning algorithm to detect one or more defects in the fused metallic powder.
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B22F 10/366 - Scanning parameters, e.g. hatch distance or scanning strategy
G01N 21/88 - Investigating the presence of flaws, defects or contamination
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B22F 10/85 - Data acquisition or data processing for controlling or regulating additive manufacturing processes
G05B 19/4099 - Surface or curve machining, making 3D objects, e.g. desktop manufacturing
B29C 64/135 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
71.
Radiation-enabled retention features for fixtureless assembly of node-based structures
Retention features are provided for joining at least two structural components in a fixtureless assembly system. A first structure including a groove may be configured to contain at least one adhesive, and a second structure may include a tongue configured to contact the at least one adhesive to join the first and second structures. The first structure may also include at least one window that receives electromagnetic (EM) radiation from an EM radiation source into the groove. The at least one adhesive is configured to cure at a first rate upon exposure to one of time or heating, and the at least one adhesive is configured to cure at a second rate faster than the first rate upon exposure to the EM radiation.
In an aspect of the disclosure, a first manufacturing cell for assembling a structure is provided. The first manufacturing cell for assembling the structure may include a plurality of first robots positioned around a common point in a first configuration, and a plurality of second robots positioned around the common point in a second configuration, the second configuration being closer to the common point than the first configuration. One of the plurality of first robots is configured to translate towards and away from the common point to interact with one of the plurality of second robots or one of the plurality of second robots is configured to translate towards and away from the common point to interact with one of the plurality of first robots.
The disclosed embodiments relate to the monitoring and control of additive manufacturing. In particular, a method is shown for removing errors inherent in thermal measurement equipment so that the presence of errors in a product build operation can be identified and acted upon with greater precision. Instead of monitoring a grid of discrete locations on the build plane with a temperature sensor, the intensity, duration and in some cases position of each scan is recorded in order to characterize one or more build operations.
B23K 31/12 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to investigating the properties, e.g. the weldability, of materials
An optical manufacturing process sensing and status indication system is taught that is able to utilize optical emissions from a manufacturing process to infer the state of the process. In one case, it is able to use these optical emissions to distinguish thermal phenomena on two timescales and to perform feature extraction and classification so that nominal process conditions may be uniquely distinguished from off-nominal process conditions at a given instant in time or over a sequential series of instants in time occurring over the duration of the manufacturing process. In other case, it is able to utilize these optical emissions to derive corresponding spectra and identify features within those spectra so that nominal process conditions may be uniquely distinguished from off-nominal process conditions at a given instant in time or over a sequential series of instants in time occurring over the duration of the manufacturing process.
G01N 21/71 - Systems in which the material investigated is excited whereby it emits light or causes a change in wavelength of the incident light thermally excited
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/00 - Data acquisition or data processing for additive manufacturing
An additive manufacturing system includes a work region having a layer of metallic powder distributed across at least a portion of the work region. The system further includes a power source, a scanning and focusing system and a processor. The processor is configured to control the power source to emit a beam of energy at a power level and to manipulate the beam of energy across the work region in a plurality of build tracks to form a part from the fused metallic powder. The processor further determines a cooling rate at a termination of each of the plurality of build tracks and controls the power level of the power source in response to the determined cooling rate.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B22F 12/90 - Means for process control, e.g. cameras or sensors
B22F 10/85 - Data acquisition or data processing for controlling or regulating additive manufacturing processes
B22F 10/368 - Temperature or temperature gradient, e.g. temperature of the melt pool
B22F 12/41 - Radiation means characterised by the type, e.g. laser or electron beam
This invention teaches a quality assurance system for additive manufacturing. This invention teaches a multi-sensor, real-time quality system including sensors, affiliated hardware, and data processing algorithms that are Lagrangian-Eulerian with respect to the reference frames of its associated input measurements. The quality system for Additive Manufacturing is capable of measuring true in-process state variables associated with an additive manufacturing process, i.e. those in-process variables that define a feasible process space within which the process is deemed nominal. The in-process state variables can also be correlated to the part structure or microstructure and can then be useful in identifying particular locations within the part likely to include defects.
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B22F 12/44 - Radiation means characterised by the configuration of the radiation means
Apparatus and methods for additively manufactured structures with augmented energy absorption properties are presented herein. Three dimensional (3D) additive manufacturing structures may be constructed with spatially dependent features to create crash components. When used in the construction of a transport vehicle, the crash components with spatially dependent additively manufactured features may enhance and augment crash energy absorption. This in turn absorbs and re-distributes more crash energy away from the vehicle's occupant(s), thereby improving the occupants' safety.
B62D 21/15 - Understructures, i.e. chassis frame on which a vehicle body may be mounted having impact absorbing means, e.g. a frame designed to permanently or temporarily change shape or dimension upon impact with another body
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B33Y 80/00 - Products made by additive manufacturing
B60R 19/03 - Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by material, e.g. composite
A node may be additively manufactured. The node may include a first surface and a second surface, and the second surface may bound a recess of the node. A structure may be inserted into the recess. A sealing member extend away from the second surface and contact the structure, such that a sealed space may be created between the node and the structure. An adhesive may be applied in the sealed space to at least partially attach the structure to the node.
Techniques for dehumidifying powder used as print material in a powder bed fusion (PBF) three-dimensional (3-D) system are disclosed. A hopper includes one or more ultrasonic transducers (UTs) positioned at strategic locations. When activated, the UTs use sound pressure at ultrasonic frequencies to agitate the powder particles held in the hopper. The movement of the particles drives moisture trapped between the particles into one or more desiccants. In various embodiments, the desiccants may be supported by desiccators suspended in the powder, such as via the casing of the hopper. In other embodiments, the desiccants may be desiccant bags provided in a desiccant insert. The moisture accumulates in the desiccants. Among other advantages, no separate thermal source is needed to dry the powder, which can be provided directly to the PBF 3-D system via the re-coater for depositing layers to form a build piece.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
A vehicle chassis is provided. The vehicle chassis may comprise one or more vehicle chassis modules or chassis substructures that are formed from a plurality of customized chassis nodes and connecting tubes. The customized chassis nodes and connecting tubes may be formed of one or more metal and/or non-metal materials. The customized chassis nodes may be formed with connecting features to which additional vehicle panels or structures may be permanently or removeably attached. The vehicle chassis modules or chassis substructures may be interchangeably and removeably connected to provide a vehicle chassis having a set of predetermined chassis safety or performance characteristics.
B62D 21/17 - Understructures, i.e. chassis frame on which a vehicle body may be mounted forming fluid or electrical conduit means or having other means to accommodate the transmission of a force or signal
B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
B33Y 80/00 - Products made by additive manufacturing
B62D 29/04 - Superstructures characterised by material thereof predominantly of synthetic material
B62D 27/02 - Connections between superstructure sub-units rigid
B62D 23/00 - Combined superstructure and frame, i.e. monocoque constructions
B62D 29/00 - Superstructures characterised by material thereof
B22F 7/08 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
An exhaust header with an integrated heat shield is disclosed. In one aspect of the disclosure, the exhaust header comprises a body including an inner wall that defines a cavity through which exhaust gases can be routed. An outer wall is integrally formed with, and radially offset from, the inner wall to define an air gap through which an airflow can be received at an input of the exhaust header and passed along a periphery of the body to collect thermal radiation and route it through an outlet duct. In some embodiments, the exhaust header is coupled to a turbocharger, which itself is coupled to an exhaust outlet of the body and separately, the air gap for effecting an airflow about the turbocharger's perimeter. Further, in various embodiments, the exhaust header is additively manufactured to produce the integrated heat shield and other header components.
Aspects are provided for retaining components of an assembly to a support, including additively manufactured (AM) parts of a vehicle chassis to an assembly table. A cartridge for securing the component to the assembly table is provided which includes a housing including at least one compartment, an adhesive disposed within the at least one compartment, a fastener removably attached to the assembly table, and a membrane lid enclosing an opening of the housing. The membrane lid is configured to receive a protruding member from the component such that the protruding member becomes adhered to the adhesive upon penetrating the membrane lid. The cartridge thus allows the component to be quickly retained in any selected position while constraining movement of the component along six degrees of freedom, thereby allowing AM and non-AM parts to be securely retained to accommodate strict tolerance and precise fit between the components of the assembly.
B23P 19/00 - Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
B62D 65/02 - Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
B23Q 3/18 - Devices holding, supporting, or positioning, work or tools, of a kind normally removable from the machine for positioning only
B25B 11/00 - Work holders or positioners not covered by groups , e.g. magnetic work holders, vacuum work holders
B62D 65/00 - Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
Techniques for providing custom formed panels for transport structures including vehicles and aircraft are disclosed. In one aspect of the disclosure, a panel for a transport structure includes a first face sheet, a second face sheet arranged opposite the first face sheet, the second face sheet comprising a different geometrical profile than the first face sheet to define a space between the first and second face sheets having a variable thickness, a core configured to occupy the space. In another aspect, a node can be additively manufactured to form the custom panels by engaging opposing face sheets. The node has an inlet port for providing a foam-like substance into the space between the face sheets to thereafter solidify into a core.
B33Y 80/00 - Products made by additive manufacturing
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
B32B 5/24 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer
E04C 1/00 - Building elements of block or other shape for the construction of parts of buildings
E04C 2/38 - Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
A multi-material three-dimensional (3-D) powder bed fusion-based (PBF) printer is disclosed. In one aspect, the 3-D PBF includes a body, a controller coupled to the body, a plurality of cartridges coupled to a print nozzle, an energy source coupled to an upper surface of the body, a deflector for deflecting an energy beam from the energy source, and a build plate on which a build piece can be 3-D printed. Each cartridge may include a slurry in which a specific print material or alloy is suspended. A depositor may selectively deposit the slurry onto the build plate to form a plurality of consecutive layers. For a given layer or a given region thereof, the controller may selectively deposit different amounts of the slurry to produce an alloy having a desired composition. A heating element may be used to vaporize the solvent in the deposited slurry. Using the deflector, the energy source can fuse the regions to sinter the deposited material and in some embodiments, to vaporize the solvent prior to sintering. In other embodiments, the slurries may include different alloys that can be selectively distributed across the layers to form a build piece having desired material characteristics.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B29C 64/129 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
B29C 64/255 - Enclosures for the building material, e.g. powder containers
A three-dimensional (3-D) printer and technique for integrating additive and non-print manufacturing operations is disclosed. In an aspect, the 3-D printer includes an energy source and a powder bed regions for selectively fusing layers of a build piece. The 3-D printer further includes a robotic arm. The 3-D printing is interrupted responsive to instructions from a controller, upon which the robotic arm may perform one or more non-printing operations using the build piece such as milling, casting, molding, pressing, and the like. Following the non-printing operations, the 3-D printing operation continues, and a resulting assembly including the build piece is produced.
B29C 69/00 - Combinations of shaping techniques not provided for in a single one of main groups , e.g. associations of moulding and joining techniques; Apparatus therefor
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B22F 3/24 - After-treatment of workpieces or articles
B25J 11/00 - Manipulators not otherwise provided for
B33Y 40/20 - Post-treatment, e.g. curing, coating or polishing
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
Techniques for providing universal interfaces between parts of a transport structure are disclosed. In one aspect of the disclosure, an apparatus for joining first and second parts of a transport structure includes an additively manufactured body having first and second surfaces. The first surface may connect to a first part such as, for example, a panel. The second surface may include a fitting for mating with a complementary fitting on a second part.
B33Y 80/00 - Products made by additive manufacturing
B29C 65/56 - Joining of preformed parts; Apparatus therefor using mechanical means
B29C 65/00 - Joining of preformed parts; Apparatus therefor
B29C 70/84 - Moulding material on preformed parts to be joined
B29C 70/72 - Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components
B29C 70/02 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements and fillers incorporated in matrix material, forming one or more layers, with or without non-reinforced or non-filled layers
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
87.
IMPACT ENERGY ABSORBER WITH INTEGRATED ENGINE EXHAUST NOISE MUFFLER
Multifunction noise suppression and crash structures are disclosed. In one aspect of the disclosure, the multifunction structure includes a body, inlet and outlet pipes, and a plurality of walls within the body that bound resonator cells and that are configured to suppress exhaust noise passing through the resonator cells from the inlet to the outlet pipes. The structure may be positioned between crash rails at the rear of the vehicle and between the engine and bumper. The walls may be generally aligned with, or near, the predicted impact direction and they may crumple in a controlled manner during an impact. In various embodiments the structure is 3D printed to enable construction of a wide diversity of geometric topologies and to minimize mass.
F01N 1/02 - Silencing apparatus characterised by method of silencing by using resonance
F01N 13/18 - Construction facilitating manufacture, assembly or disassembly
B60R 19/02 - Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
B62D 21/15 - Understructures, i.e. chassis frame on which a vehicle body may be mounted having impact absorbing means, e.g. a frame designed to permanently or temporarily change shape or dimension upon impact with another body
B33Y 80/00 - Products made by additive manufacturing
Apparatuses for dynamically sensing infrared (IR) radiation in an electron beam powder bed fusion (EB-PBF) printer are provided. A radiation collector receives radiation from a surface of the powder bed. An IR-transparent material rejects one or more non-IR wavelengths, and a lens focuses the IR radiation onto an optical fiber. The IR radiation is carried from the vacuum chamber of the printer to a sensor, where IR information is determined based on the received IR radiation. The IR information may be received from the sensor and used by the print controller to modify one or more parameters, such as beam intensity or scanning rate, on the fly or during the next print cycle. An occlusion member can be used to selectively block or expose the radiation collector to protect the radiation collector from condensation of vapor from vaporization of particles at high temperatures.
B29C 64/371 - Conditioning of environment using an environment other than air, e.g. inert gas
B29C 64/268 - Arrangements for irradiation using electron beams [EB]
B29C 64/255 - Enclosures for the building material, e.g. powder containers
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
89.
ULTRAVIOLET RADIATION SENSING AND BEAM CONTROL IN ELECTRON BEAM ADDITIVE MANUFACTURING
In various aspects, an apparatus for an electron-beam powder bed fusion (EB-PBF) printer includes a radiation collector configured to collect radiation in an ultraviolet (UV) spectrum at a powder bed surface within a vacuum chamber during an electron beam scanning cycle of EB-PBF operation, an optical fiber configured to be transparent to the radiation in the UV spectrum and configured to receive the radiation at the powder bed surface via the radiation collector, and a processor configured to receive one or more extracted wavelengths of radiation in the UV spectrum based on the radiation carried on the optical fiber.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
Techniques for cleaning a print chamber using a gas exchange structure and a re-coater are introduced. The gas exchange structure is coupled to the coater, and the two move in a same direction to benefit from the gas flow. In an embodiment, the gas exchange structure includes a manifold. Further, in an embodiment, a travelling wall may be coupled to a longitudinal axis of the re-coater in order to keep separate the clean chamber from the dirty chamber. The result is that gas contaminants caused largely by the fusion and melting processes are removed from the powder bed and chamber at each cycle, and the resulting 3-D produced component maintains a very high quality for a long period of time.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
Self-supporting 3-D printed chassis structures are disclosed. Self-supporting ribs are selectively printed to walls of the structure to meet desired dynamic stiffness targets while maintaining a reduced mass. The self-supporting ribs can be used as both support structures (e.g., for outer walls) during 3-D printing and as stiffening structures when the chassis structure is in operation. In an embodiment, the chassis structure is printed such that no support structures are needed. Topology optimization can enable remaining unneeded internal ribs or supports to be removed, and a high inner spatial volume between ribs can be maintained to make maximum use of the part. In various embodiments, wall thicknesses can be maintained at or below 1-2 millimeters, which further reduces mass.
B62D 29/04 - Superstructures characterised by material thereof predominantly of synthetic material
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
B33Y 80/00 - Products made by additive manufacturing
92.
Methods and apparatus for additively manufactured endoskeleton-based transport structures
Some embodiments of the present disclosure relate to an additively manufactured transport structure. The transport structure includes cavities into which components that use an external interface are inserted. A plurality of components are assembled and integrated into the vehicle. In an embodiment, the components and frame are modular, enabling reparability and replacement of single parts in the event of isolated failures.
B23K 26/03 - Observing, e.g. monitoring, the workpiece
B23K 26/40 - Removing material taking account of the properties of the material involved
B23K 26/00 - Working by laser beam, e.g. welding, cutting or boring
B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
G06F 30/15 - Vehicle, aircraft or watercraft design
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
B22F 10/25 - Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
B29C 64/124 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
B62D 27/02 - Connections between superstructure sub-units rigid
B22F 10/18 - Formation of a green body by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B22F 12/46 - Radiation means with translatory movement
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B23K 101/00 - Articles made by soldering, welding or cutting
B22F 3/115 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor by spraying molten metal, i.e. spray sintering, spray casting
A computing system may direct a first robotic arm to a first position based on a first set of coordinates. The computing system may cause the first robotic arm to engage with a first structure based on the first position of the first robotic arm. Further, the computing system may direct the first robotic arm to a second position based on a second set of coordinates such that the first structure is brought within a joining proximity of a second structure without a fixture retaining the first structure and without a fixture retaining the second structure, wherein the first structure is configured to be joined with the second structure when the first and second structures are within the joining proximity, the joining proximity being a proximity at which the first and second structures can be joined together.
Techniques for pre-heating the powders of layer deposited on the powder bed during a 3-D print process conducted by a 3-D printer are disclosed. A re-coater includes a heat source that pre-heats the deposited layer as a leveling member of the re-coater smooths the layer onto the powder bed. In some embodiments, the re-coater reheats the powder bed following the selective fusing of a layer by an energy beam source. The consistent pre-heating and re-heating of the powder directly on the surface of the powder bed maximally reduces damage, cracks, dimensional flaws, and other artifacts created by excessive thermal gradients in the case where heat is not used.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 40/00 - Auxiliary operations or equipment, e.g. for material handling
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
B23K 26/14 - Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
Techniques for joining nodes and subcomponents are presented herein. An additively manufactured first node or subcomponent has a groove. An additively manufactured second node or subcomponent has a tongue configured to extend into and mate with the groove to form a tongue-and-groove connection between the first and second node or subcomponent. In some aspects, the tongue-groove connection may extend substantially around a periphery of the node or subcomponent. In other aspects, a first subcomponent having a fluid pipe interface may be coupled via a tongue-groove connection to a second subcomponent having a fluid pipe interface, thereby enabling fluid to flow between subcomponents of the resulting integrated component.
B32B 3/10 - Layered products essentially comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products essentially having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material
F16H 57/029 - Gearboxes; Mounting gearing therein characterised by means for sealing gearboxes, e.g. to improve airtightness
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 37/24 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
B32B 3/06 - Layered products essentially comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products essentially having particular features of form characterised by features of form at particular places, e.g. in edge regions for attaching the product to another member, e.g. to a support
F16H 57/032 - Gearboxes; Mounting gearing therein characterised by the materials used
B22F 7/08 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
F16H 57/04 - Features relating to lubrication or cooling
This invention teaches a multi-sensor quality inference system for additive manufacturing. This invention still further teaches a quality system that is capable of discerning and addressing three quality issues: i) process anomalies, or extreme unpredictable events uncorrelated to process inputs; ii) process variations, or difference between desired process parameters and actual operating conditions; and iii) material structure and properties, or the quality of the resultant material created by the Additive Manufacturing process. This invention further teaches experimental observations of the Additive Manufacturing process made only in a Lagrangian frame of reference. This invention even further teaches the use of the gathered sensor data to evaluate and control additive manufacturing operations in real time.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 64/386 - Data acquisition or data processing for additive manufacturing
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
G05B 19/418 - Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control (DNC), flexible manufacturing systems (FMS), integrated manufacturing systems (IMS), computer integrated manufacturing (CIM)
B29C 64/393 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
This disclosure describes an additive manufacturing system that includes a build plane having a first region and a second region. Multiple energy source can be positioned above the build plane and configured to direct energy into the first and second regions of the build plane. The system includes optical sensors configured to monitor an intensity of light emitted from the energy sources. A processor associated with the additive manufacturing system is configured to adjust the sensor outputs in response to the energy sources coming into close proximity.
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
B33Y 50/02 - Data acquisition or data processing for additive manufacturing for controlling or regulating additive manufacturing processes
B23K 26/06 - Shaping the laser beam, e.g. by masks or multi-focusing
B23K 26/082 - Scanning systems, i.e. devices involving movement of the laser beam relative to the laser head
B23K 26/03 - Observing, e.g. monitoring, the workpiece
B29C 64/00 - Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
B22F 12/00 - Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
B22F 10/00 - Additive manufacturing of workpieces or articles from metallic powder
Techniques for inlaying a composite material within a tooling shell are disclosed. In one aspect, an additively manufactured tooling shell is provided, into which a composite material is inlaid and cured. A surface of the tooling shell is provided with indentations or another mechanism to enable adherence between the composite material and the tooling shell. The resulting integrated structure is used as a component in a transport structure.
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B29C 70/30 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 70/84 - Moulding material on preformed parts to be joined
B29C 70/54 - Component parts, details or accessories; Auxiliary operations
B29K 709/00 - Use of inorganic materials not provided for in groups , for preformed parts, e.g. for inserts
This disclosure describes various system and methods for monitoring photons emitted by a heat source of an additive manufacturing device. Sensor data recorded while monitoring the photons can be used to predict metallurgical, mechanical and geometrical properties of a part produced during an additive manufacturing operation. In some embodiments, a test pattern can be used to calibrate an additive manufacturing device.
G01N 21/71 - Systems in which the material investigated is excited whereby it emits light or causes a change in wavelength of the incident light thermally excited
B33Y 50/00 - Data acquisition or data processing for additive manufacturing
B33Y 30/00 - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Details thereof or accessories therefor
G01N 21/00 - Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
H01L 21/66 - Testing or measuring during manufacture or treatment
G01N 21/84 - Systems specially adapted for particular applications
Wishbone-style control arm assemblies for a vehicle and methods for assembling the same are disclosed. A control arm assembly includes a first elongated segment having a first connection feature at one end of the first segment. The control arm assembly includes a second elongated segment having a second connection feature at one end of the second segment. Opposite longitudinal ends of the first and second segments may include third and fourth connection features, respectively, that are configured to interface with the vehicle. The first and second connection features are aligned to form an aperture that extends at least partially through the first and segment connection features, through which a bushing is press-fit and then swaged to form a strong connection that reduces or eliminates the need for mechanical fasteners or adhesive bonds. The bushing connection independently enables the control arm to maintain a secure connection between segments during operation of the control arm when assembled in the vehicle.
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