SYSTEMS AND METHODS FOR IMPLEMENTING NODE TO NODE CONNECTIONS IN MECHANIZED ASSEMBLIES

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. 1. An apparatus , comprising:an additively manufactured first node having a groove; andan additively manufactured second node having a tongue extending into the groove to form a tongue-and-groove connection between the first and second node.2. The apparatus of claim 1 , wherein the first node further comprises a channel extending from an exterior surface of the first node to the groove for adhesive injection.3. The apparatus of claim 1 , further comprising adhesive between the tongue-and-groove.4. The apparatus of claim 1 , wherein the tongue comprises a centering feature.5. The apparatus of claim 1 , wherein the centering feature comprises a proximal portion of the tongue having a clearance fit with the groove.6. The apparatus of claim 1 , wherein the first and second nodes cooperate to form a sealant reservoir on each side of the tongue-and-groove connection.7. The apparatus of claim 1 , further comprising a standoff tab extending across the first and second nodes.8. An apparatus claim 1 , comprising:an additively manufactured first subcomponent comprising a tongue structure disposed along a first peripheral region thereof; andan additively manufactured second subcomponent comprising a groove structure disposed along a second peripheral region ...

APPARATUS AND METHODS FOR ADDITIVELY MANUFACTURING LATTICE STRUCTURES

Apparatus and methods for additively manufacturing lattice structures are disclosed herein. Lattice structures are analyzed and automatedly generated with respect to surface proximity. A lattice structure is varied by changing lattice element variables including lattice density. An automated approach using CAD algorithms or programs can generate data for lattice structures based on design variables including volume, surface, angle, and position. 1. A method for additively manufacturing a component comprising:receiving a model of the component to be additively manufactured;identifying one or more regions of the component requiring structural support; andautomatedly generating at least one self-supporting lattice network in the identified one or more regions to produce a modified model.2. The method of claim 1 , wherein the at least one self-supporting lattice network comprises a permanent part of the component.3. The method of claim 1 , wherein the at least one self-supporting lattice network is removable after the component is additively manufactured.4. The method of claim 1 , wherein the automatedly generating the at least one self-supporting lattice network comprises generating lattice elements having different densities.5. The method of claim 1 , wherein the automatedly generating the at least one self-supporting lattice network comprises generating lattice elements having different lengths.6. The method of claim 1 , wherein the automatedly generating the at least one self-supporting lattice network comprises generating lattice elements having different cross-sectional areas.7. The method of claim 1 , wherein the automatedly generating the at least one self-supporting lattice network comprises generating a plurality of levels of lattice elements claim 1 , each level having a different number of lattice elements.8. The method of claim 1 , wherein the automatedly generating the at least one self-supporting lattice network further comprises generating a plurality of ...

ASSEMBLING STRUCTURES COMPRISING 3D PRINTED COMPONENTS AND STANDARDIZED COMPONENTS UTILIZING ADHESIVE CIRCUITS

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.

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. 1. A transport structure , comprising:a 3-D printed frame comprising a structure configured to accept road loads and to protect an occupant in an impact event;a plurality of cavities, protruding through the 3-D printed frame, for receiving components that use an external interface; anda body disposed over an exterior surface of the 3-D printed frame.2. The transport structure of claim 1 , further comprising a set of general components integrated at least in part in the 3-D printed frame.3. The transport structure of claim 2 , wherein at least a portion of the set of general components comprise modular components.4. The transport structure of claim 3 , wherein a subset of the set of general components comprises the components that use an external interface5. The transport structure of claim 1 , wherein the body is 3-D printed.6. The transport structure of claim 1 , wherein the 3-D printed frame is 3-D printed in a single rendering.7. The transport structure of claim 1 , wherein the body is co-printed with the 3-D printed frame in sections or in a single rendering.8. The transport structure of claim 1 , further comprising at least one nosecone coupled to one or both of a front and rear surface of the 3-D printed frame.9. The transport structure of claim 8 , wherein the at least one nosecone is covered with a section of foam or lattice.10. The transport structure of claim 9 , wherein the foam or lattice is 3-D printed.11. The transport structure of wherein the at least one nosecone coupled to the front surface of the 3-D printed frame is configured ...

APPARATUS AND METHODS FOR REMOVABLE SUPPORT STRUCTURES IN ADDITIVE MANUFACTURING

Systems and methods of support structures in powder-bed fusion (PBF) are provided. Support structures can be formed of bound powder, which can be, for example, compacted powder, compacted and sintered powder, powder with a binding agent applied, etc. Support structures can be formed of non-powder support material, such as a foam. Support structures can be formed to include inductive components that can be used to facilitate removal of the support structures in the presence of an external magnetic field. Additionally, support structures can be formed to break when a fluid, such as air or water, creates a force and/or pressure at a connection point interface. 1. A method for additively manufacturing a component , comprising:receiving a data model of a structure comprising the component supported by a conductive support material coupled to at least one inductive element;additively manufacturing the structure based on the data model;placing the structure in a first magnetic field; andenergizing the at least one inductive element to generate a second magnetic field having a direction opposite the first magnetic field and configured to break the support material from the component.2. The method of claim 1 , wherein the at least one inductive element comprises additively manufactured coils configured to provide a predetermined inductance range.3. The method of claim 1 , wherein energizing the at least one inductive element comprises applying a voltage to the at least one inductive element claim 1 , the voltage having a magnitude sufficient to break the support material without damaging the component.4. The method of claim 1 , wherein the support material is tapered at a point of contact to the component to facilitate removal of the support material.5. The method of claim 1 , wherein the additively manufacturing the structure comprises positioning the conductive support material such that a direction and polarity of the second magnetic field facilitates removal of the ...

INTERCONNECTED DEFLECTABLE PANEL AND NODE AND METHODS FOR PRODUCING SAME

Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node having a socket. The apparatus includes a panel interconnected with node. The panel includes opposing surface layers and a core between at least a portion of the surface layers. The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.

ADAPTIVE PRODUCTION SYSTEM

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. 1. An apparatus for manufacturing a product , comprising:a design apparatus;an assembly apparatus; anda control apparatus, coupled to the design apparatus and the assembly apparatus, wherein the control apparatus receives input information from the design apparatus and the assembly apparatus, and provides output information for altering at least one parameter used in the manufacture of the product.2. The apparatus of claim 1 , wherein the control apparatus maintains at least one first parameter at a desired value while altering the at least one parameter used by the design apparatus or the assembly apparatus.3. The apparatus of claim 2 , wherein the at least one first parameter is at least one of a strength claim 2 , a crashworthiness claim 2 , cost claim 2 , or an assembly time.4. The apparatus of claim 1 , wherein the output information is delivered to the design apparatus and the assembly apparatus for changing the operation of the design apparatus or the assembly apparatus.5. The apparatus of claim 1 , further comprising a testing apparatus.6. The apparatus of claim 5 , wherein an output of the testing apparatus is used by the control apparatus to alter at least one parameter used by the design apparatus or the assembly apparatus.7. The apparatus of claim 1 , wherein the control apparatus comprises a monitoring apparatus.8. The apparatus of claim 7 , wherein the monitoring ...

SYSTEMS AND METHODS FOR JOINING NODE AND TUBE STRUCTURES

Connections between nodes and tubes are provided. An apparatus can include additively manufactured first and second nodes, a tube, and an interconnect connecting the tube to the first and second nodes. An apparatus can include a node having an end portion with inner and outer concentric portions forming an annular gap therebetween, and a tube having an end portion extending into the gap. 1. An apparatus , comprising:an additively manufactured first node;an additively manufactured second node;a tube; andan interconnect connecting the tube to the first and second nodes.2. The apparatus of claim 1 , wherein the interconnect comprises a base and a shaft extending from the base.3. The apparatus of claim 2 , wherein the first and second nodes are adhered to the base and the tube is adhered to the shaft.4. The apparatus of claim 3 , wherein the base comprises a first portion adhered to a complementary portion of the first node and a second portion adhered to a complementary portion of the second node.5. The apparatus of claim 3 , wherein the shaft extends into the tube and is adhered to the inner surface of the tube.6. The apparatus of claim 1 , wherein the interconnect comprises a first element adhered to the first node and the tube claim 1 , and a second element adhered to the second node and the tube.7. The apparatus of claim 6 , wherein the first and second elements are arranged to form a slot claim 6 , and wherein the tube extends through the slot.8. The apparatus of claim 6 , wherein the first node comprises a first bracket supporting the first element and the second node comprises a second bracket supporting the second element.9. The apparatus of claim 1 , further comprising:a spacer structure arranged between two or more of the first node, second node, tube, and interconnect.10. The apparatus of claim 9 , wherein the spacer structure includes a seal.11. The apparatus of claim 9 , wherein the spacer structure includes adhesive.12. An apparatus claim 9 , comprising:a ...

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.

SYSTEMS AND METHODS FOR JOINING NODE AND TUBE STRUCTURES

Connections between nodes and tubes are provided. An apparatus can include additively manufactured first and second nodes, a tube, and an interconnect connecting the tube to the first and second nodes. An apparatus can include a node having an end portion with inner and outer concentric portions forming an annular gap therebetween, and a tube having an end portion extending into the gap. 1. An apparatus , comprising:a node having an end portion with inner and outer concentric portions forming an annular gap therebetween; anda tube having an end portion extending into the annular gap.2. The apparatus of claim 1 , wherein the annular gap has a depth from a surface of the end portion of the node claim 1 , and wherein a diameter of the annular gap increases with distance from the surface over at least a portion of the depth.3. The apparatus of claim 2 , wherein a section of the end portion of the tube flares outward along the annular gap over said at least the portion of the depth.4. The apparatus of claim 3 , wherein the section of the end portion of the tube that flares outward comprises dry carbon fiber.5. The apparatus of claim 3 , wherein the node comprises a channel extending from an exterior surface of the node to the annular gap for resin injection.6. The apparatus of claim 5 , wherein the section of the end portion of the tube that flares outward comprises carbon fiber and resin from the channel.7. The apparatus of claim 5 , wherein the node further comprises a second channel extending from an exterior of the node to the annular gap for applying a vacuum during resin injection.8. The apparatus of claim 1 , further comprising:a spacer structure arranged between the node and the tube.9. The apparatus of claim 8 , wherein the spacer structure includes a seal. This application is a divisional of U.S. patent application Ser. No. 15/671,894, filed Aug. 8, 2017, the content of which is incorporated herein by reference in its entirety.The present disclosure relates ...

SUPPORT STRUCTURES IN ADDITIVE MANUFACTURING

Systems and methods of support structures in powder-bed fusion (PBF) are provided. Support structures can be formed of bound powder, which can be, for example, compacted powder, compacted and sintered powder, powder with a binding agent applied, etc. Support structures can be formed of non-powder support material, such as a foam. Support structures can be formed to include resonant structures that can be removed by applying a resonance frequency. Support structures can be formed to include structures configured to melt when electrical current is applied for easy removal. 1. An apparatus for powder-bed fusion , comprising:a depositor that deposits a plurality of layers of a powder material;an energy beam source that generates an energy beam;a deflector that applies the energy beam to fuse the powder material in a first area in a first one of the layers; anda powder fixer that binds the powder material in a second area in a second one of the layers, wherein the second area is underneath the first area.2. The apparatus of claim 1 , wherein a third one of the layers includes a third area of powder material underneath the second area claim 1 , and the deflector and the powder fixer are configured such that the powder material in the third area is not fused and not bound.3. The apparatus of claim 1 , wherein the powder fixer includes a compactor that compacts the powder material in the second area.4. The apparatus of claim 3 , wherein the compactor includes a mechanical roller.5. The apparatus of claim 3 , wherein the compactor includes a mechanical press.6. The apparatus of claim 1 , wherein the powder fixer includes a heater that partially sinters the powder material in the second area.7. The apparatus of claim 1 , wherein the powder fixer includes an applicator that applies a binding agent to the powder material in the second area.8. The apparatus of claim 7 , wherein the binding agent includes a liquid.9. The apparatus of claim 7 , wherein the binding agent includes a ...

APPARATUS AND METHODS FOR JOINING PANELS

Apparatus and methods for joining panels are presented. Panels may be commercial off the shelf (COTS) panels and/or additively manufactured panels; and panels can be joined using an additively manufactured interconnect unit. Notches and protrusions can be formed in the panels and in the interconnect unit to facilitate the connection of the panels with the interconnect unit. In another approach a ribbed triangular prism can be manufactured using three dimensional (3D) printing. The panels can then be joined by inserting the ribbed triangular prism between the panels and by using an adhesive for bonding. 1. An apparatus , comprising:a first panel and a second panel, each of the first and second panels having a panel feature; andan interconnect comprising a first interconnect feature engaged with the panel feature for the first panel and a second interconnect feature engaged with the panel feature for the second panel.2. The apparatus of claim 1 , wherein the interconnect is additively manufactured.3. The apparatus of claim 1 , wherein the each of the panel features comprises a notch and each of the first and the second interconnect features comprises a projection.4. The apparatus of claim 1 , wherein the each of the panel features comprises a projection and each of the first and the second interconnect features comprises a notch.5. The apparatus of claim 1 , wherein the interconnect comprises fluid transport tubing.6. The apparatus of claim 1 , further comprising tubing coupled to the interconnect for adhesive injection between the each of the panel features and its corresponding one of the first and the second interconnect features.7. The apparatus of claim 1 , wherein at least one of the first and second panels is additively manufactured.8. The apparatus of claim 1 , wherein at least one of the first and second panels is a honeycomb sandwich panel.9. An apparatus claim 1 , comprising:a first panel and a second panel configured for assembly in a transport structure; ...

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.

METHODS AND APPARATUS FOR FORMING NODE TO PANEL JOINTS

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 ...

APPARATUS AND METHODS FOR REMOVABLE SUPPORT STRUCTURES IN ADDITIVE MANUFACTURING

Systems and methods of support structures in powder-bed fusion (PBF) are provided. Support structures can be formed of bound powder, which can be, for example, compacted powder, compacted and sintered powder, powder with a binding agent applied, etc. Support structures can be formed of non-powder support material, such as a foam. Support structures can be formed to include inductive components that can be used to facilitate removal of the support structures in the presence of an external magnetic field. Additionally, support structures can be formed to break when a fluid, such as air or water, creates a force and/or pressure at a connection point interface. 1. An apparatus for supporting a structure in a powder bed fusion system , comprising:a bed into which powder layers are deposited and selectively fused to form a build piece;a voltage source electrically coupled to a region of unfused powder under an overhang of the build piece and configured to apply a static charge to the region,wherein the application of static charge is configured to provide a combinational force to the unfused powder in the region sufficient to support the overhang during build piece formation.2. The apparatus of claim 1 , wherein the voltage source is configured to remove the static charge after a designated number of powder layers is selectively fused.3. The apparatus of claim 1 , wherein an orientation of the bed is modified to reduce a volume of unfused powder necessary for use in the region during the 3-D print.4. A method for supporting a structure in a powder bed fusion system claim 1 , comprising:depositing a plurality of powder layers in a bed;selectively fusing the plurality of powder layers to form a build piece; andapplying a static charge to a region of unfused powder under an overhang of the build piece,wherein the application of static charge provides a combinational force to the unfused powder in the region sufficient to support the overhang during build piece formation.5. ...

APPARATUS AND METHODS FOR OPTIMIZATION OF POWDER REMOVAL FEATURES IN ADDITIVELY MANUFACTURED COMPONENTS

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. 1. A method for automatedly inserting powder removal features in an additively manufactured component , the method comprising:receiving a model of a component to be additively manufactured;automatedly determining optimal size and location of one or more apertures in the component for powder removal; andupdating the model to include the one or more determined powder removal apertures.2. The method of claim 1 , further comprising additively manufacturing the component based on the updated model.3. The method of claim 2 , further comprising removing trapped powder from the additively manufactured component using the one or more powder removal apertures.4. The method of claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises evaluating potential gravitational advantages for facilitating powder removal.5. The method of claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises selecting an aperture size based at least in part on a type of material to be used as powder particles in the additive manufacturing of the component.6. The method of claim 1 , wherein the automatedly determining optimal size and location of the one or more apertures comprises evaluating loading and boundary conditions for the component.7. The method of claim 1 , further comprising automatedly determining geometry and location of one or more powder channels for ...

APPARATUS AND METHODS FOR OPTIMIZATION OF POWDER REMOVAL FEATURES IN ADDITIVELY MANUFACTURED COMPONENTS

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.

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. 1. An apparatus comprising:an additively manufactured node having a receptacle extending into the node, the receptacle including a first surface, and the node including an exterior surface, a first channel connecting the exterior surface to the first surface, and a second channel connecting the exterior surface to the first surface;a structure inserted in the receptacle, the structure including a second surface opposing the first surface;a seal member arranged between the node and the structure, wherein an adhesive region between the node and the structure is bounded by the first surface, the second surface, and a surface of the seal member, the adhesive region connecting to each of the first and second channels; andan adhesive arranged in the adhesive region, wherein the adhesive adjoins the seal member surface and attaches the first surface to the second surface.2. The apparatus of claim 1 , further comprising:a fill material filling the first and second channels.3. The apparatus of claim 1 , wherein the receptacle includes a hole.4. The apparatus of claim 1 , wherein the adhesive region is hermetically sealed.5. The ...

METHODS AND APPARATUS FOR FORMING NODE TO PANEL JOINTS

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. 1. A node comprising:a base comprising at least a first side and a second side, the first side and the second side forming a recess in the base;a first port and a second port coupled to the base;at least one adhesive region disposed on a first surface of the first side and a second surface of the second side; andat least one channel coupled between the first port and the second port and configured to fill the adhesive regions with an adhesive.2. The node of claim 1 , wherein the channel runs serially from the first port to the second port through the at least one adhesive region on the first side and the second side by using apertures arranged on opposing sides of each adhesive region.3. The node of claim 2 , wherein the channel is configured to enable transmission of the adhesive in parallel through the ...

APPARATUS AND METHODS FOR CONNECTING TUBES IN TRANSPORT STRUCTURES

Apparatus and methods for joining tubes in transport structures are presented herein. A part having an attached node with a socket can be joined with tubes. The tubes can be placed along nonparallel axes within the socket; and a wedge can be used to secure the tubes to the socket. The wedge can be secured between the tubes by using a fastener, such as a blind fastener; alternatively, or additionally, the wedge can be secured between the tubes using an adhesive. 1. An apparatus , comprising:a part;a node comprising a first portion attached to the part and a second portion having a socket; andfirst and second tubes extending from the socket along non-parallel axes.2. The apparatus of claim 1 , wherein the part is additively manufactured.3. The apparatus of claim 1 , wherein the part is an extrusion.4. The apparatus of claim 3 , wherein the extrusion is hollow.5. The apparatus of claim 1 , wherein the node is additively manufactured.6. The apparatus of claim 1 , wherein at least one of the first and second tubes are additively manufactured.7. The apparatus of claim 1 , further comprising a wedge between the first and second tubes to secure the first and second tubes to the socket.8. The apparatus of claim 7 , wherein the wedge is removable.9. The apparatus of claim 7 , wherein the wedge is additively manufactured.10. The apparatus of claim 7 , wherein the wedge is tapered.11. The apparatus of claim 7 , wherein the wedge comprises opposing concave surfaces claim 7 , each of the concave surfaces being engaged with a different one of the first and second tubes.12. The apparatus of claim 7 , wherein at least one spacer is inserted between the first and second tubes and the socket claim 7 , the at least one spacer separating a surface of the first and second tubes and a surface of the socket.13. The apparatus of claim 12 , wherein the surface of the first and second tubes is separated from the surface of the socket so as to reduce galvanic corrosion.14. The apparatus of ...

METHODS AND APPARATUS FOR ADDITIVELY MANUFACTURED EXOSKELETON-BASED TRANSPORT STRUCTURES

Some embodiments of the present disclosure relate to additively manufactured vehicle exterior structures, designed to enclose the vehicle surface and support required operational loads. The vehicle structure includes cavities into which components that require an external interface are inserted. A plurality of components are assembled and integrated into the vehicle structure. The structure may be 3-D printed using multiple printing techniques applied in parallel or in series. In an embodiment, the components and structure are modular, use multiple materials and manufacturing techniques, and enable reparability and replacement of single parts. 1. An apparatus for assembly into a transport structure , comprising:an additively-manufactured (AM) structure comprising an exterior surface, the AM structure configured to accept operational loads and to protect an occupant in an event of impact,wherein the exterior surface comprises a plurality of cavities for housing components that use an external interface.2. The apparatus of claim 1 , wherein the AM structure comprises an exoskeleton.3. The apparatus of claim 2 , wherein the AM structure further comprises an interior surface.4. The apparatus of claim 3 , wherein the structure comprises at least one of a honeycomb matrix and a lattice structure arranged between inner surfaces of the interior and exterior surfaces.5. The apparatus of claim 4 , wherein the honeycomb matrix or the lattice structure is co-printed with at least one of the interior and exterior surfaces of the 3-D printed frame.6. The apparatus of claim 2 , wherein the AM structure is configured to provide a majority of impact protection associated with the transport structure.7. The apparatus of wherein impact protection capability of the AM structure eliminates a need for crash rails.8. The apparatus of claim 1 , further comprising a set of general components integrated in part or in whole within the AM structure claim 1 , wherein the set of general ...

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. 1. An apparatus , comprising:a first additively manufactured (AM) part configured to connect to a second part via an adhesive applied at an interface between the first and second parts; anda retention element arranged for placement across the interface and securing the first and second parts during at least application of the adhesive or curing of the adhesive.2. The apparatus of claim 1 , wherein the first AM part comprises a first interface feature configured to connect to a second interface feature of the second part claim 1 , andwherein the interface is defined at least in part by the first and second interface features.3. The apparatus of claim 1 , wherein the retention element comprises a first member protruding from the first AM part and configured to connect to a second member protruding from the second part.4. The apparatus of claim 1 , wherein the first and second parts each comprise a protrusion claim 1 , each protrusion having a generally flat portion claim 1 , the flat portion of the protrusion corresponding to first part configured to be flush claim 1 , at least in part claim 1 , against the flat portion of the protrusion corresponding to the second part when the first and second parts are positioned for ...

SYSTEMS AND METHODS FOR BRIDGING COMPONENTS

One aspect is an apparatus including a node having a socket configured to receive a component and a detachable additively manufactured nozzle co-printed with the node and arranged for adhesive injection between the component and the socket. Another aspect is an additively manufactured apparatus including a first additively manufactured component having an area configured to receive a second additively manufactured component. The first component includes an adhesive channel for injecting adhesive into the area when the second component is being connected to the first component. Another 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. 1. An apparatus , comprising:a node having a first portion configured to support a metal sheet and a second portion configured to support a component to thereby couple the metal sheet to the component.2. The apparatus of claim 1 , further comprising the metal sheet supported by the first portion of the node and the component supported by the second portion of the node.3. The apparatus of claim 2 , wherein the component comprises a metal component.4. The apparatus of claim 2 , wherein the component comprises an additively manufactured component.5. The apparatus of claim 2 , wherein the component comprises a panel.6. The apparatus of claim 1 , wherein the first portion of the node comprises a first socket and the second portion of the node comprises a second socket.7. The apparatus of claim 6 , wherein the first socket is located at one end of the node and the second socket is located at an opposite end of the node.8. The apparatus of claim 6 , wherein the node is elongated between the one end of the node and the opposite end of the node.9. The apparatus of claim 6 , wherein the node further comprises an ...

APPARATUS AND METHODS FOR CONNECTING NODES TO PANELS IN TRANSPORT STRUCTURES

Apparatus and methods for joining nodes, extrusions, and panels are presented herein. Nodes, extrusions, and panels can be joined together using adhesive joining techniques. The adhesive joining techniques can be applied to additively manufactured nodes or extrusions, and sandwich panels. Sandwich panels can be additively manufactured and/or commercial off the shelf (COTS) components. There can be more than one type of a joint formed by the joining techniques. Exemplary types of j oints can use a liquid adhesive in conjunction with a vacuum and/or a film foam adhesive. 1. An apparatus , comprising:a component having a socket;a panel having an end portion positioned within the socket; andan adhesive between the end portion of the panel and the socket to adhere the panel to the component.2. The apparatus of claim 1 , wherein the panel is additively manufactured.3. The apparatus of claim 1 , wherein the component comprises a channel extending from an external surface of the component to the socket for adhesive injection.4. The apparatus of claim 3 , wherein the component further comprises a second channel extending from an external surface of the component to the socket for applying a vacuum during adhesive injection.5. The apparatus of claim 1 , further comprising a sealant between the end portion of the panel and the socket to seal the adhesive in the socket.6. The apparatus of claim 5 , wherein the sealant between the end portion of the panel and the socket reduces galvanic corrosion by forming a gap.7. The apparatus of claim 1 , further comprising a spacer between the end portion of the panel and the socket claim 1 , the spacer separating a surface of the panel from a surface of the socket.8. The apparatus of claim 7 , wherein the surface of the panel is separated from the surface of the socket so as to reduce galvanic corrosion.9. The apparatus of claim 1 , wherein the panel comprises a plurality of adhesive patches extending across an edge of the end portion of ...

Apparatus and methods for additively manufactured structures with augmented energy absorption properties

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.

Structures and methods for high volume production of complex structures using interface nodes

A high precision Interface Node is disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. The Interface Node may connect with another component or a Linking Node. The Interface Node is manufactured to achieve high precision functionality while enabling volume production. Current additive manufacturing technologies allow for the printing of high precision features to be manufactured, but generally this is performed at a slower rate. Consequently, in one aspect, the size of the Interface Nodes is reduced in order to overcome at least part of the slower production volume caused by creating the high precision Interface Nodes. The components and Linking Nodes to which the Interface Node is connected may only have basic features and functions. Accordingly, this latter category of components may use a high print rate and thus high production volume. In other embodiments, these low precision components may also be produced using a non-print manufacturing technology, such as casting, forging, etc., that may provide the requisite high throughput, or to high precision machined parts that lack the geometric flexibility of the Interface Node. In an embodiment, the Interface Nodes may be connected to other components via a Linking Node.

APPARATUS AND METHODS FOR CONNECTING NODES TO TUBES IN TRANSPORT STRUCTURES

Apparatus and methods for joining nodes to tubes with node to tube joints are presented herein. Joining techniques allow the connection of additively manufactured nodes to tubes. In an embodiment, at least one node may be joined to a tube and may be a part of a vehicle chassis. The node to tube joint connection incorporates adhesive bonding between the node to tube to realize the connection. Sealants may be used to provide sealed regions for adhesive injection, which are housed in sealing interfaces co-printed with the additively manufactured nodes. Additionally, seals may act as isolators and reduce galvanic corrosion. 1. An apparatus , comprising: a node wall having a perimeter;', 'a first sealing interface around the perimeter, and', 'a first adhesive path around the perimeter and bounded on a first side by the first sealing interface., 'a node comprising2. The apparatus of claim 1 , further comprising a second sealing interface claim 1 , the first adhesive path being bounded on a second side by the second sealing interface.3. The apparatus of claim 2 , wherein the first sealing interface claim 2 , the second sealing interface claim 2 , and the node wall form a first annular region.4. The apparatus of claim 3 , further comprising a port.5. The apparatus of claim 4 , wherein the port is an adhesive port directly connected to the first annular region.6. The apparatus of claim 4 , wherein the port is an outlet port directly connected to the first annular region.7. The apparatus of claim 4 , wherein the port is recessed.8. The apparatus of claim 4 , wherein the port protrudes.9. The apparatus of claim 4 , wherein the port is a hole.10. The apparatus of claim 3 , further comprising a tube claim 3 , the first sealing interface claim 3 , the second sealing interface claim 3 , the node wall and a wall of the tube form a sealant chamber.11. The apparatus of claim 1 , wherein the first sealing interface comprises a mechanical seal.12. The apparatus of claim 11 , wherein ...

Assembling structures comprising 3d printed components and standardized components utilizing adhesive circuits

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.

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. 1. A multifunction apparatus for a vehicle , comprising:a muffler including a body having a plurality of walls that bound an array of resonator cells, the resonator cells arranged between inlet and outlet pipes to suppress exhaust noise;wherein the walls are configured to controllably deform during an impact event.2. The apparatus of claim 1 , wherein the muffler comprises Inconel or titanium.3. The apparatus of claim 1 , wherein the muffler comprises a material configured to controllably deform at a temperature of at least 800 degrees Celsius.4. The apparatus of claim 1 , wherein the muffler is 3D printed.5. The apparatus of claim 4 , wherein the muffler comprises a plurality of powder holes to enable removal of loose powder from within hollow portions of the body after the muffler is 3D printed.6. The apparatus of claim 4 , further comprising a co-printed radiation shield surrounding an outer surface of the body and separated from the outer surface by an air gap.7. The apparatus of claim 6 , wherein the radiation shield comprises walls shaped to conform to the body and configured to reduce an outflow of thermal radiation due to exhaust gasses in the muffler.8. The apparatus of claim 1 , being configured to be positioned ...

SYSTEMS AND METHODS FOR CO-CASTING OF ADDITIVELY MANUFACTURED INTERFACE NODES

Systems and methods for co-casting of additively manufactured, high precision Interface Nodes are disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. Co-casting of Interface Nodes by casting a part onto the Interface Node results in a hybrid structure comprising the cast part and the additively manufactured Interface Node. The interface node may include at least one of a node-to-tube connection, node-to-panel connection, or a node-to-extrusion connection. In an embodiment, engineered surfaces may be provided on the Interface Node to improve the blend between the Interface Node and the cast part during the co-casting process. 1. An apparatus , comprising:an additively manufactured node; anda cast part, the cast part cast onto the additively manufactured node to from a hybrid part including the additively manufactured node and the cast part.2. The apparatus of claim 1 , wherein the additively manufactured node comprises an interface node.3. The apparatus of claim 2 , wherein the interface node comprises at least one of a node-to-extrusion connection claim 2 , node-to-panel connection claim 2 , or a node-to-tube connection.4. The apparatus of claim 1 , wherein the additively manufactured node is configured to meet a melting point requirement.5. The apparatus of claim 1 , wherein the additively manufactured node are configured to meet a high-strength requirement.6. The apparatus of claim 1 , wherein the additively manufactured node further comprises an engineered surface.7. The apparatus of claim 1 , wherein the cast part is cast onto the additively manufactured node using a casting tool.8. The apparatus of claim 1 , wherein the additively manufactured node further comprises an anti-rotation feature.9. The apparatus of claim 1 , wherein the additively manufactured node further comprises a groove for a sealant.10. A method claim 1 , comprising:additively manufacturing a node; andcasting a ...

Methods and apparatuses for sealing mechanisms for realizing adhesive connections with additively manufactured components

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. In an exemplary embodiment,

END EFFECTOR FEATURES FOR ADDITIVELY MANUFACTURED COMPONENTS

One aspect is an apparatus including an additively manufactured component including a surface with an end effector feature, the end effector feature co-additively manufactured with the additively manufactured component and configured to be gripped by a corresponding end effector on a robot. In an aspect, the end effector feature includes a recess in the surface. In another aspect, the recess includes an angled face. In an aspect, the recess has a teardrop shape. An aspect further includes an identification feature. In an aspect, the end effector feature includes a plurality of recesses in the surface. In another aspect, the end effector feature enables a 3-point kinematic self-aligning positive control lock. 1. An apparatus , comprising:an additively manufactured component including a surface with an end effector feature, the end effector feature configured to be gripped by a corresponding end effector on a robot.2. The apparatus of claim 1 , wherein the end effector feature comprises one of an additively manufactured end effector feature manufactured separate from the additively manufactured component claim 1 , a co-additively manufactured end effector feature co-additively manufactured with the additively manufactured component claim 1 , or an alternatively manufactured end effector feature manufactured separate from the additively manufactured component.3. The apparatus of claim 1 , wherein the end effector feature comprises a recess in the surface.4. The apparatus of claim 3 , wherein the recess has a teardrop shape.5. The apparatus of claim 3 , further comprising an identification feature.6. The apparatus of claim 1 , wherein the end effector feature comprises a plurality of recesses in the surface.7. The apparatus of claim 6 , wherein bottom surfaces of the plurality of recesses are coplanar.8. The apparatus of claim 6 , wherein the plurality of recesses comprises three recesses.9. The apparatus of claim 8 , further comprising an identification feature ...

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. 1. An apparatus comprising:an additively manufactured node having a receptacle extending into the node, the receptacle including a first surface, and the node including an exterior surface, a first channel connecting the exterior surface to the first surface, and a second channel connecting the exterior surface to the first surface;a structure inserted in the receptacle, the structure including a second surface opposing the first surface;a seal member arranged between the node and the structure, wherein an adhesive region between the node and the structure is bounded by the first surface, the second surface, and a surface of the seal member, the adhesive region connecting to each of the first and second channels; andan adhesive arranged in the adhesive region, wherein the adhesive adjoins the seal member surface and attaches the first surface to the second surface.2. The apparatus of claim 1 , further comprising:a fill material filling the first and second channels.3. The apparatus of claim 1 , wherein the receptacle includes a hole.4. The apparatus of claim 1 , wherein the adhesive region is hermetically sealed.5. The ...

SYSTEMS AND METHODS FOR ADDITIVE MANUFACTURING OF TRANSPORT STRUCTURES

Systems and methods for additive manufacturing of vehicles are provided. An additive manufacturing apparatus can include a printer that additively manufactures structures for a vehicle, and multiple analysis components. Each analysis component can receive information based on a design model of the vehicle and analyze the information based on an analysis factor. Each analysis component analyzes the information based on a different analysis factor. An integrator can receives the analyzed information from the analysis components, update the design model based on the analyzed information, and determine whether the updated design model satisfies criteria. If the updated design model satisfies the criteria, the integrator determines printing instructions for the printer to print one or more structures of the vehicle based on the updated design model, and if the updated design model does not satisfy the criteria, the integrator sends information based on the updated design model to the analysis components. 1. An additive manufacturing apparatus , comprising:a printer that additively manufactures structures for a vehicle;a plurality of analysis components, each analysis component being configured to receive information based on a design model of the vehicle and to analyze the information based on an analysis factor, wherein each analysis component analyzes the information based on a different analysis factor than the other analysis components; andan integrator that receives the analyzed information from the analysis components, updates the design model based on the analyzed information, and determines whether the updated design model satisfies criteria,wherein, if the updated design model satisfies the criteria, the integrator determines printing instructions for the printer to print one or more structures of the vehicle based on the updated design model,and if the updated design model does not satisfy the criteria, the integrator sends information based on the updated ...

APPARATUS AND METHODS FOR SEALING POWDER HOLES IN ADDITIVELY MANUFACTURED PARTS

Apparatus and methods for sealing powder holes in additively manufactured parts are presented herein. Powder holes are co-printed to facilitate post processing sealing. Embodiments include co-printed caps, friction welded caps, rivets, silicone plugs, co-printed tangs, multiple micro holes, layup, and spin forming. By using one or more of the above techniques, powder holes can be sealed on additively manufactured parts. 1. An apparatus comprising:an exterior structure comprising an inner surface and an external surface;an internal lattice structure coupled to the inner surface and configured to mechanically support the exterior structure; andan aperture within the exterior structure, the aperture exposing a portion of the internal lattice structure.2. The apparatus of claim 1 , wherein the internal lattice structure is honeycomb.3. The apparatus of claim 1 , wherein the internal lattice structure is additively manufactured and the aperture is configured for powder removal.4. The apparatus of claim 1 , wherein the exterior structure is a vehicle panel.5. The apparatus of claim 1 , further comprising an overlay structure configured to cover the aperture.6. The apparatus of claim 5 , wherein the overlay structure is attached to the external surface with an adhesive.7. The apparatus of claim 5 , wherein the overlay structure comprises a composite material.8. The apparatus of claim 7 , wherein the composite material is carbon fiber.9. The apparatus of claim 7 , wherein the composite material is Kevlar.10. The apparatus of claim 7 , wherein the overlay structure is a prepreg.11. The apparatus of claim 10 , wherein the overlay structure further comprises a lip overlapping the aperture.12. A method for additive manufacturing comprising:providing an exterior structure comprising an inner surface, an external surface, and an aperture;providing an internal lattice structure; andcoupling the internal lattice structure to the inner surface to provide support to the exterior ...

Flexible tooling system and method for manufacturing of composite structures

A system and method is provided for manufacturing a composite structure. In an exemplary aspect, the system includes multiple flexible tooling plates that are interlocked to each other to form a tooling surface for forming a composite structure to be manufactured. Moreover, the system includes an actuator array connected to the flexible plates and that can move the flexible plates relative to each other to adjust a contour of the tooling surface to correspond to a design contour of the composite structure to be manufactured.

NODE WITH CO-PRINTED LOCATING FEATURES AND METHODS FOR PRODUCING SAME

Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node having a socket. The apparatus includes one or more locating features co-printed with the node. The one or more locating features are configured to locate an end portion of a component in the socket. 1. An apparatus , comprising:an additively manufactured node having a socket; andone or more locating features co-printed with the node, wherein the one or more locating features are configured to locate an end portion of a component in the socket.2. The apparatus of claim 1 , wherein the one or more locating features are arranged within the socket to maintain a gap between the component and the socket when the component is engaged in the socket.3. The apparatus of claim 2 , wherein the one or more locating features comprise a plurality of deformable barbs.4. The apparatus of claim 2 , wherein the one or more locating features comprise a plurality of bumps.5. The apparatus of claim 1 , wherein the one or more locating features comprise one or more tapered shims.6. The apparatus of claim 1 , wherein the one or more locating features comprise a plate and a plurality of struts coupling the plate to an interior surface of the socket.7. The apparatus of claim 1 , further comprising a detachable additively manufactured nozzle co-printed with the node and arranged for adhesive injection between the component and the socket.8. The apparatus of claim 1 , wherein the socket comprises a projection configured to engage a notch in the component to position the component in the socket.9. The apparatus of claim 1 , wherein the one or more locating features comprises a pair of spaced apart locators positioned on an internal surface of the socket opposite the socket opening claim 1 , the locators being configured to provide a friction or slip fit with an edge of the end portion of the component.10. The apparatus of claim 9 , wherein the component is positioned in the socket and ...

INTERCONNECTED DEFLECTABLE PANEL AND NODE AND METHODS FOR PRODUCING SAME

Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node having a socket. The apparatus includes a panel interconnected with node. The panel includes opposing surface layers and a core between at least a portion of the surface layers. The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel. 1. An apparatus , comprising:an additively manufactured node having a socket; anda panel interconnected with the node, the panel comprising opposing surface layers and a core between at least a portion of the surface layers, wherein the socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.2. The apparatus of claim 1 , wherein the surface layers on the end portion of the panel are without at least a portion of the core between them.3. The apparatus of claim 2 , wherein the panel further comprises a material between the surface layers on the end portion of the panel claim 2 , wherein when the stiffness of the core is reduced claim 2 , the material has greater flexibility than the core.4. The apparatus of claim 2 , wherein the panel further comprises adhesive filler material comprising a plurality of microballoons between the surface layers on the end portion of the panel.5. The apparatus of claim 1 , wherein a section of the core extends between the surface layers of the end portion of the panel claim 1 , and wherein the section of the core comprises a notch.6. The apparatus of claim 5 , wherein the adhesive extends from the notch into the socket.7. The apparatus of claim 6 , further comprising a sealant between the panel and the socket to seal the adhesive in the socket.8. The apparatus of claim 5 , wherein the socket comprises a tapered portion that narrows with distance from the socket opening claim 5 , and wherein the notch is compressed by the tapered portion.9. The apparatus of claim 5 , wherein the socket comprises a ...

NODE WITH CO-PRINTED INTERCONNECT AND METHODS FOR PRODUCING SAME

Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node. The apparatus includes an additively manufactured interconnect co-printed with the node. The interconnect is configured to connect the node to a component. 1. An apparatus , comprising:an additively manufactured node; andan additively manufactured interconnect co-printed with the node, wherein the interconnect is configured to connect the node to a component.2. The apparatus of claim 1 , wherein the interconnect is further configured to connect the node to the component comprising a tube.3. The apparatus of claim 2 , wherein the node comprises a socket and the interconnect comprises a proximal end that together with the socket forms a joint therebetween that provides a range of linear motion between the interconnect and the node.4. The apparatus of claim 2 , wherein the node comprises a socket and the interconnect comprises a proximal end that together with the socket forms a rotating joint therebetween.5. The apparatus of claim 4 , wherein the proximal end of the interconnect has a spherical shape.6. The apparatus of claim 4 , wherein the proximal end of the interconnect has an ellipsoidal shape.7. The apparatus of claim 2 , wherein the proximal end of the interconnect has a dovetail shape.8. The apparatus of claim 2 , wherein the interconnect comprises a distal end configured to slide into an end portion of the tube.9. The apparatus of claim 2 , wherein the interconnect comprises a distal end having an end cap configured to slide over an end portion of the tube.10. The apparatus of claim 1 , wherein the node comprises a channel extending from an exterior surface of the node to the socket for adhesion injection.11. The apparatus of claim 10 , wherein the node comprises a second channel extending from an exterior surface of the node to the socket for enabling at least a partial vacuum environment during adhesion injection.12. The apparatus of claim 10 , ...

3-D-PRINTED COMPONENTS INCLUDING FASTENERS AND METHODS FOR PRODUCING SAME

One aspect is an apparatus including an additively manufactured first component and a captive nut contained within the first component for interconnecting the first component to a second component. Another aspect is an apparatus including a first additively manufactured component having a hole and a second additively manufactured component having a socket. The apparatus further includes a pin having a head engaging a surface of the first component and a shaft extending from the head through the hole in the first component and into the socket of the second component. Another aspect is an apparatus including first and second panels. The apparatus also includes a bolt having a head and a shaft extending from the head and a nut located at a distal end of the shaft. The first and seconds panels may be sandwiched between the bolt and nut to interconnect the first and second panels. 1. An apparatus , comprising:an additively manufactured first component; anda captive nut contained within the first component for interconnecting the first component to a second component.2. The apparatus of claim 1 , wherein the captive nut is co-printed with the first component.3. The apparatus of claim 1 , wherein the captive nut comprises threads.4. The apparatus of claim 3 , wherein the threads are additively manufactured.5. The apparatus of claim 1 , wherein the captive nut floats within the first component.6. The apparatus of claim 1 , wherein the captive nut is prevented from rotating by the first component.7. The apparatus of claim 1 , further comprising an additively manufactured semi-spherical housing co-printed with the first component and the nut claim 1 , wherein the nut is contained within the first component by the additively manufactured semi-spherical housing.8. The apparatus of claim 1 , further comprising a shim which together with the first component forms a cavity and allows the nut to move along an axial axis of the nut.9. The apparatus of claim 8 , wherein the shim is ...

ADDITIVE MANUFACTURING-ENABLED PLATFORM FOR MODULAR CONSTRUCTION OF VEHICLES USING DEFINITION NODES

A platform for building a plurality of vehicle types is disclosed. In an embodiment, a facility may include a processing system for designing a plurality of definition nodes for a vehicle and identifying a relative position for each definition node. Based on the design, the internal volume and other vehicle parameters can be determined. The facility includes a 3-D printer for additively manufacturing the definition nodes. In an embodiment, a plurality of commercial-off-the-shelf (COTS) parts are acquired and the definition nodes are designed to interface with the COTS parts. The facility may also include a station, or primary location where the major portions of the vehicle are assembled. In another embodiment, multiple such geographically-distributed facilities can be used, such that one facility can manufacture a desired vehicle type on behalf of another facility, e.g., in the event of an overflow. 1. A method for manufacturing a vehicle , comprising:designing a plurality of definition nodes for the vehicle;identifying a relative position for each definition node;additively manufacturing the definition nodes; andassembling the vehicle with the definition nodes in the identified positions.2. The method of claim 1 , wherein the positions define a vehicle profile comprising one or more modular systems.3. The method of claim 1 , wherein the positions are based at least in part on one or more internal volume requirements of the vehicle.4. The method of claim 1 , further comprising claim 1 , upon identifying the position for each definition node;designing or acquiring a plurality of panels and vehicle parts; andidentifying a position of the panels and vehicle parts relative to the position of each definition node.5. The method of claim 1 , further comprising:designing the vehicle to include a plurality of commercial off-the-shelf (COTS) parts;designing the definition nodes to interface with the COTS parts to produce modular features; andmanufacturing the vehicle ...

3-d-printed components including fasteners and methods for producing same

Apparatus and methods for connecting nodes to tubes in transport structures

Apparatus and methods for joining nodes to tubes with node to tube joints are presented herein. Joining techniques allow the connection of additively manufactured nodes to tubes. In an embodiment, at least one node may be joined to a tube and may be a part of a vehicle chassis. The node to tube joint connection incorporates adhesive bonding between the node to tube to realize the connection. Sealants may be used to provide sealed regions for adhesive injection, which are housed in sealing interfaces co-printed with the additively manufactured nodes. Additionally, seals may act as isolators and reduce galvanic corrosion.

Apparatus and methods for connecting nodes to tubes in transport structures

Apparatus and methods for joining nodes to tubes with node to tube joints are presented herein. Joining techniques allow the connection of additively manufactured nodes to tubes. In an embodiment, at least one node may be joined to a tube and may be a part of a vehicle chassis. The node to tube joint connection incorporates adhesive bonding between the node to tube to realize the connection. Sealants may be used to provide sealed regions for adhesive injection, which are housed in sealing interfaces co-printed with the additively manufactured nodes. Additionally, seals may act as isolators and reduce galvanic corrosion.

An interconnected deflectable panel and node and methods for producing same

Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node having a socket. The apparatus includes a panel interconnected with node. The panel includes opposing surface layers and a core between at least a portion of the surface layers. The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.

Node with co-printed interconnect and methods for producing same

Systems and methods for implementing node to node connections in mechanized assemblies

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.

Node with co-printed interconnect and methods for producing same

Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node. The apparatus includes an additively manufactured interconnect co-printed with the node. The interconnect is configured to connect the node to a component.

Systems and methods for additive manufacturing of transport structures

Systems and methods for additive manufacturing of vehicles are provided. An additive manufacturing apparatus can include a printer that additively manufactures structures for a vehicle, and multiple analysis components. Each analysis component can receive information based on a design model of the vehicle and analyze the information based on an analysis factor. Each analysis component analyzes the information based on a different analysis factor. An integrator can receives the analyzed information from the analysis components, update the design model based on the analyzed information, and determine whether the updated design model satisfies criteria. If the updated design model satisfies the criteria, the integrator determines printing instructions for the printer to print one or more structures of the vehicle based on the updated design model, and if the updated design model does not satisfy the criteria, the integrator sends information based on the updated design model to the analysis components.

Flexible tooling system and method for manufacturing of composite structures

A system and method is provided for manufacturing a composite structure. In an exemplary aspect, the system includes multiple flexible tooling plates that are interlocked to each other to form a tooling surface for forming a composite structure to be manufactured. Moreover, the system includes an actuator array connected to the flexible plates and that can move the flexible plates relative to each other to adjust a contour of the tooling surface to correspond to a design contour of the composite structure to be manufactured.

Apparatus and methods for connecting tubes in transport structures

Apparatus and methods for joining tubes in transport structures are presented herein. A part having an attached node with a socket can be joined with tubes. The tubes can be placed along nonparallel axes within the socket; and a wedge can be used to secure the tubes to the socket. The wedge can be secured between the tubes by using a fastener, such as a blind fastener; alternatively, or additionally, the wedge can be secured between the tubes using an adhesive.

Apparatus and methods for additively manufacturing lattice structures

Apparatus and methods for additively manufacturing lattice structures are disclosed herein. Lattice structures are analyzed and automatedly generated with respect to surface proximity. A lattice structure is varied by changing lattice element variables including lattice density. An automated approach using CAD algorithms or programs can generate data for lattice structures based on design variables including volume, surface, angle, and position.

Apparatus and methods for additively manufactured structures with augmented energy absorption properties

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.

Apparatus and methods for removable support structures in additive manufacturing

Systems and methods of support structures in powder-bed fusion (PBF) are provided. Support structures can be formed of bound powder, which can be, for example, compacted powder, compacted and sintered powder, powder with a binding agent applied, etc. Support structures can be formed of non-powder support material, such as a foam. Support structures can be formed to include inductive components that can be used to facilitate removal of the support structures in the presence of an external magnetic field. Additionally, support structures can be formed to break when a fluid, such as air or water, creates a force and/or pressure at a connection point interface.

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.

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.

Systems and methods for co-casting of additively manufactured interface nodes

Adaptive production system

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.

Methods and apparatus for additively manufactured exoskeleton-based transport structures

Some embodiments of the present disclosure relate to additively manufactured vehicle exterior structures, designed to enclose the vehicle surface and support required operational loads. The vehicle structure includes cavities into which components that require an external interface are inserted. A plurality of components are assembled and integrated into the vehicle structure. The structure may be 3-D printed using multiple printing techniques applied in parallel or in series. In an embodiment, the components and structure are modular, use multiple materials and manufacturing techniques, and enable reparability and replacement of single parts.

Impact energy absorber with integrated engine exhaust noise muffler

Apparatus and methods for connecting tubes in transport structures

Apparatus and methods for joining tubes in transport structures are presented herein. A part having an attached node with a socket can be joined with tubes. The tubes can be placed along nonparallel axes within the socket; and a wedge can be used to secure the tubes to the socket. The wedge can be secured between the tubes by using a fastener, such as a blind fastener; alternatively, or additionally, the wedge can be secured between the tubes using an adhesive.

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.

End effector features for additively manufactured components

One aspect is an apparatus including an additively manufactured component including a surface with an end effector feature, the end effector feature co-additively manufactured with the additively manufactured component and configured to be gripped by a corresponding end effector on a robot. In an aspect, the end effector feature includes a recess in the surface. In another aspect, the recess includes an angled face. In an aspect, the recess has a teardrop shape. An aspect further includes an identification feature. In an aspect, the end effector feature includes a plurality of recesses in the surface. In another aspect, the end effector feature enables a 3-point kinematic self-aligning positive control lock.

Node with co-printed interconnect and methods for producing same

Assembling structures comprising 3d printed components and standardized components utilizing adhesive circuits

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.

Structures and methods for high volume production of complex structures using interface nodes

A high precision Interface Node is disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. The Interface Node may connect with another component or a Linking Node. The Interface Node is manufactured to achieve high precision functionality while enabling volume production. Current additive manufacturing technologies allow for the printing of high precision features to be manufactured, but generally this is performed at a slower rate. Consequently, in one aspect, the size of the Interface Nodes is reduced in order to overcome at least part of the slower production volume caused by creating the high precision Interface Nodes. The components and Linking Nodes to which the Interface Node is connected may only have basic features and functions. Accordingly, this latter category of components may use a high print rate and thus high production volume. In other embodiments, these low precision components may also be produced using a non-print manufacturing technology, such as casting, forging, etc., that may provide the requisite high throughput, or to high precision machined parts that lack the geometric flexibility of the Interface Node. In an embodiment, the Interface Nodes may be connected to other components via a Linking Node.

Structurally integrated heat-exchangers

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.

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.

Apparatus and methods for additively manufactured structures with augmented energy absorption properties

Apparatus and methods for optimization of powder removal features in additively manufactured components

輸送構造の付加製造のためのシステムおよび方法

【課題】車両の付加製造のためのシステムおよび方法を提供する。【解決手段】付加製造装置は、車両の構造を付加製造するプリンタと、複数の解析コンポーネントとを含むことができる。各解析コンポーネントは、車両の設計モデルに基づく情報を受信して、解析ファクタに基づき情報を解析することができる。各解析コンポーネントは、異なる解析ファクタに基づいて情報を解析する。統合器が、解析された情報を解析コンポーネントから受信し、解析された情報に基づいて設計モデルを更新し、更新された設計モデルが基準を満足するかどうかを判断することができる。更新された設計モデルが基準を満たせば、統合器は、更新された設計モデルに基づいて車両の１つ以上の構造をプリンタがプリントするためのプリント命令を決定し、更新された設計モデルが基準を満足しなければ、統合器は、更新された設計モデルに基づく情報を解析コンポーネントに送信する。【選択図】図２

Methods and apparatuses for sealing mechanisms for realizing adhesive connections with additively manufactured components

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.

Apparatus and methods for additively manufacturing lattice structures

Apparatus and methods for additively manufacturing lattice structures are disclosed herein. Lattice structures are analyzed and automatedly generated with respect to surface proximity. A lattice structure is varied by changing lattice element variables including lattice density. An automated approach using CAD algorithms or programs can generate data for lattice structures based on design variables including volume, surface, angle, and position.

Apparatus and methods for additively manufacturing lattice structures

Apparatus and methods for additively manufactured structures with augmented energy absorption properties

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.

Apparatus and methods for additively manufactured structures with augmented energy absorption properties

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.

Apparatus and methods for removable support structures in additive manufacturing

Systems and methods of support structures in powder-bed fusion (PBF) are provided. Support structures can be formed of bound powder, which can be, for example, compacted powder, compacted and sintered powder, powder with a binding agent applied, etc. Support structures can be formed of non-powder support material, such as a foam. Support structures can be formed to include inductive components that can be used to facilitate removal of the support structures in the presence of an external magnetic field. Additionally, support structures can be formed to break when a fluid, such as air or water, creates a force and/or pressure at a connection point interface.

Support structures in additive manufacturing

Systems and methods of support structures in powder-bed fusion (PBF) are provided. Support structures can be formed of bound powder, which can be, for example, compacted powder, compacted and sintered powder, powder with a binding agent applied, etc. Support structures can be formed of non-powder support material, such as a foam. Support structures can be formed to include resonant structures that can be removed by applying a resonance frequency. Support structures can be formed to include structures configured to melt when electrical current is applied for easy removal.

Support structures in additive manufacturing

Systems and methods of support structures in powder-bed fusion (PBF) are provided. Support structures can be formed of bound powder, which can be, for example, compacted powder, compacted and sintered powder, powder with a binding agent applied, etc. Support structures can be formed of non-powder support material, such as a foam. Support structures can be formed to include resonant structures that can be removed by applying a resonance frequency. Support structures can be formed to include structures configured to melt when electrical current is applied for easy removal.

Apparatus and methods for removable support structures in additive manufacturing

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.

Methods and apparatuses for sealing mechanisms for realizing adhesive connections with additively manufactured components

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.

Systems and methods for co-casting of additively manufactured interface nodes

Systems and methods for co-casting of additively manufactured, high precision Interface Nodes are disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. Co-casting of Interface Nodes by casting a part onto the Interface Node results in a hybrid structure comprising the cast part and the additively manufactured Interface Node. The interface node may include at least one of a node-to-tube connection, node-to-panel connection, or a node-to-extrusion connection. In an embodiment, engineered surfaces may be provided on the Interface Node to improve the blend between the Interface Node and the cast part during the co-casting process.

End effector features for additively manufactured components

Systems and methods for co-casting of additively manufactured interface nodes

Systems and methods for co-casting of additively manufactured, high precision Interface Nodes are disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. Co-casting of Interface Nodes by casting a part onto the Interface Node results in a hybrid structure comprising the cast part and the additively manufactured Interface Node. The interface node may include at least one of a node-to-tube connection, node-to-panel connection, or a node-to-extrusion connection. In an embodiment, engineered surfaces may be provided on the Interface Node to improve the blend between the Interface Node and the cast part during the co-casting process.

Methods and apparatus for additively manufactured exoskeleton-based transport structures

Some embodiments of the present disclosure relate to additively manufactured vehicle exterior structures, designed to enclose the vehicle surface and support required operational loads. The vehicle structure includes cavities into which components that require an external interface are inserted. A plurality of components are assembled and integrated into the vehicle structure. The structure may be 3-D printed using multiple printing techniques applied in parallel or in series. In an embodiment, the components and structure are modular, use multiple materials and manufacturing techniques, and enable reparability and replacement of single parts.

Adaptive production system

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.

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.

Apparatus and methods for joining panels

Apparatus and methods for joining panels are presented. Panels may be commercial off the shelf (COTS) panels and/or additively manufactured panels; and panels can be joined using an additively manufactured interconnect unit. Notches and protrusions can be formed in the panels and in the interconnect unit to facilitate the connection of the panels with the interconnect unit. In another approach a ribbed triangular prism can be manufactured using three dimensional (3D) printing. The panels can then be joined by inserting the ribbed triangular prism between the panels and by using an adhesive for bonding.

End effector features for additively manufactured components

One aspect is an apparatus including an additively manufactured component including a surface with an end effector feature, the end effector feature co-additively manufactured with the additively manufactured component and configured to be gripped by a corresponding end effector on a robot. In an aspect, the end effector feature includes a recess in the surface. In another aspect, the recess includes an angled face. In an aspect, the recess has a teardrop shape. An aspect further includes an identification feature. In an aspect, the end effector feature includes a plurality of recesses in the surface. In another aspect, the end effector feature enables a 3-point kinematic self-aligning positive control lock.

End effector features for additively manufactured components

One aspect is an apparatus including an additively manufactured component including a surface with an end effector feature, the end effector feature co-additively manufactured with the additively manufactured component and configured to be gripped by a corresponding end effector on a robot. In an aspect, the end effector feature includes a recess in the surface. In another aspect, the recess includes an angled face. In an aspect, the recess has a teardrop shape. An aspect further includes an identification feature. In an aspect, the end effector feature includes a plurality of recesses in the surface. In another aspect, the end effector feature enables a 3-point kinematic self-aligning positive control lock.

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.

Apparatus and methods for optimization of powder removal features in additively manufactured components

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.

Energy unit cells for primary vehicle structure

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.

Methods and apparatuses for sealing mechanisms for realizing adhesive connections with additively manufactured components