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 ...

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.

Systems and methods for co-printed or concurrently assembled hinge structures

Systems and methods of co-printing a unitary hinge are provided. The unitary hinge may be co-printed using an additive manufacturing process. The unitary hinge includes a hinge pin that is substantially cylindrical in shape. The unitary hinge also includes a knuckle which surrounds a portion of the hinge pin and is configured to be manipulated about the hinge pin. The hinge pin is fabricated in situ with the knuckle such that further assembly is unnecessary. The unitary hinge may also include retention mechanism to retain the hinge within the knuckle without substantially restricting the knuckle from being rotated about the hinge pin. The unitary hinge may further be configured with a fluid port which may, for example, be used to provide a lubricant to an area between the hinge pin and the knuckle or to vacuum powder material or debris from the area.

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 universal interface between parts in transport structures

Techniques for providing universal interfaces between parts of a transport structure are disclosed. In one aspect of the disclosure, an apparatus for joining first and second parts of a transport structure includes an additively manufactured body having first and second surfaces. The first surface may connect to a first part such as, for example, a panel. The second surface may include a fitting for mating with a complementary fitting on a second part.

3D-printed tooling shells

Techniques for producing panels such as for use in a vehicle, boat, aircraft or other transport structure or mechanical structure using a 3-D-printed tooling shell are disclosed. A 3-D printer may be used to produce a tooling shell containing Invar and/or some other material for use in molding the panels. A channel may be formed in a 3-D printed tooling shell for enabling resin infusion, vacuum generation or heat transfer. Alternatively, or in addition to, one or more hollow sections may be formed within the 3-D printed tooling shell for reducing a weight of the shell. The panel may be molded using the 3-D printed tooling shell.

Automated wrapping of components in transport structures

An automated wrapping technique for vehicle components is disclosed. A component to be wrapped is secured to a fixture, which in turn is coupled to an actuator. A grabber arm grabs a length of wrap from a feed roll. The grabber arm removes the backing and spreads the wrap over the component. The actuator pushes the component upward until the wrap contacts the component surface. An applicator may concurrently smooth the wrap and evacuate trapped air. The wrap may be cut around the periphery of the component, and hemmed. A controller provides instructions to automate the wrapping mechanism.

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 ...

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.

3D-printed tooling and methods for producing same

Techniques for 3-D printing a tooling shell for use in producing panels for a transport structure, such as an automobile, boat, aircraft, or other vehicle, or other mechanical structure, are disclosed. A 3-D printer may be used to produce a tooling shell containing Invar and/or some other material for use in molding the panels. A channel may be formed in a 3-D printed tooling shell for enabling resin infusion, vacuum generation or heat transfer. Alternatively, or in addition to, one or more hollow sections may be formed within the 3-D printed tooling shell for reducing a weight of the shell.

Methods and apparatus for manufacturing optimized panels and other composite structures

The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing ...

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.

3D-PRINTED TOOLING SHELLS

Techniques for producing panels such as for use in a vehicle, boat, aircraft or other transport structure or mechanical structure using a 3-D-printed tooling shell are disclosed. A 3-D printer may be used to produce a tooling shell containing Invar and/or some other material for use in molding the panels. A channel may be formed in a 3-D printed tooling shell for enabling resin infusion, vacuum generation or heat transfer. Alternatively, or in addition to, one or more hollow sections may be formed within the 3-D printed tooling shell for reducing a weight of the shell. The panel may be molded using the 3-D printed tooling shell.

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 ...

3D-PRINTED TOOLING AND METHODS FOR PRODUCING SAME

Techniques for 3-D printing a tooling shell for use in producing panels for a transport structure, such as an automobile, boat, aircraft, or other vehicle, or other mechanical structure, are disclosed. A 3-D printer may be used to produce a tooling shell containing Invar and/or some other material for use in molding the panels. A channel may be formed in a 3-D printed tooling shell for enabling resin infusion, vacuum generation or heat transfer. Alternatively, or in addition to, one or more hollow sections may be formed within the 3-D printed tooling shell for reducing a weight of the shell. 1. A method of three-dimensional (3-D) printing a tooling shell suitable for producing a composite panel for a transport or other mechanical structure , comprising:receiving instructions for printing the tooling shell, the instructions based on a data model of the tooling shell;receiving material comprising Invar; andprinting the tooling shell based on the instructions using the material.2. The method of claim 1 , wherein the material comprises substantially Invar.3. The method of claim 1 , wherein the printing the tooling shell comprises forming a channel in the tooling shell to enable resin infusion claim 1 , vacuum generation claim 1 , or heat transfer.4. The method of claim 3 , wherein the printing the tooling shell further comprises forming a hollow section in the tooling shell.5. The method of claim 1 , wherein the printing the tooling shell comprises forming a hollow section in the tooling shell.6. A method of three-dimensional (3-D) printing a tooling shell suitable for producing a panel for a transport or other mechanical structure claim 1 , comprising:receiving instructions for printing the tooling shell, the instructions based on a data model of the tooling shell;receiving material; andprinting the tooling shell based on the instructions using the material, wherein the printing the tooling shell comprises forming a hollow section in the tooling shell.7. The method 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.

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.

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 ...

METHODS AND APPARATUS FOR MANUFACTURING OPTIMIZED PANELS AND OTHER COMPOSITE STRUCTURES

The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component. 1. A panel for use in a transport structure , comprising;at least one face sheet; andan additively manufactured (AM) core affixed to the at least one face sheet and configured to provide a varying strength across at least a portion of the AM core for supporting expected load conditions determined across all three coordinate axes (x,y,z).2. The panel of claim 1 , wherein the at least one face sheet comprises a non-planar contour.3. The panel of claim 1 , wherein the at least one face sheet comprises a variable thickness.4. The panel of claim 1 , wherein the AM core comprises a homogenous material.5. The panel of claim 1 , wherein the AM core is configured to provide a varying strength along a plurality of ...

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 ...

Methods for producing panels using 3D-printed tooling shells

Techniques for producing panels such as for use in a vehicle, boat, aircraft or other transport structure or mechanical structure using a 3-D-printed tooling shell are disclosed. A 3-D printer may be used to produce a tooling shell containing Invar and/or some other material for use in molding the panels. A channel may be formed in a 3-D printed tooling shell for enabling resin infusion, vacuum generation or heat transfer. Alternatively, or in addition to, one or more hollow sections may be formed within the 3-D printed tooling shell for reducing a weight of the shell. The panel may be molded using the 3-D printed tooling shell.

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 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.

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.

Robotic assembly of transport structures using on-site additive manufacturing

Techniques for flexible, on-site additive manufacturing of components or portions thereof for transport structures are disclosed. An automated assembly system for a transport structure may include a plurality of automated constructors to assemble the transport structure. In one aspect, the assembly system may span the full vertically integrated production process, from powder production to recycling. At least some of the automated constructors are able to move in an automated fashion between the station under the guidance of a control system. A first of the automated constructors may include a 3-D printer to print at least a portion of a component and to transfer the component to a second one of the automated constructors for installation during the assembly of the transport structure. The automated constructors may also be adapted to perform a variety of different tasks utilizing sensors for enabling machine-learning.

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

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.

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.

Methods and apparatuses for universal interface between parts in transport structures

Techniques for providing universal interfaces between parts of a transport structure are disclosed. In one aspect of the disclosure, an apparatus for joining first and second parts of a transport structure includes an additively manufactured body having first and second surfaces. The first surface may connect to a first part such as, for example, a panel. The second surface may include a fitting for mating with a complementary fitting on a second part.

ROBOTIC ASSEMBLY OF TRANSPORT STRUCTURES USING ON-SITE ADDITIVE MANUFACTURING

Techniques for flexible, on-site additive manufacturing of components or portions thereof for transport structures are disclosed. An automated assembly system for a transport structure may include a plurality of automated constructors to assemble the transport structure. In one aspect, the assembly system may span the full vertically integrated production process, from powder production to recycling. At least some of the automated constructors are able to move in an automated fashion between the station under the guidance of a control system. A first of the automated constructors may include a 3-D printer to print at least a portion of a component and to transfer the component to a second one of the automated constructors for installation during the assembly of the transport structure. The automated constructors may also be adapted to perform a variety of different tasks utilizing sensors for enabling machine-learning.

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.

AUTOMATED WRAPPING OF COMPONENTS IN TRANSPORT STRUCTURES

An automated wrapping technique for vehicle components is disclosed. A component to be wrapped is secured to a fixture, which in turn is coupled to an actuator. A grabber arm grabs a length of wrap from a feed roll. The grabber arm removes the backing and spreads the wrap over the component. The actuator pushes the component upward until the wrap contacts the component surface. An applicator may concurrently smooth the wrap and evacuate trapped air. The wrap may be cut around the periphery of the component, and hemmed. A controller provides instructions to automate the wrapping mechanism. 1. An apparatus for automated film wrapping of vehicle components , comprising:a grabber arm mounted to a base at a first end and configured to grab a length of film from a feed roll and position the length of film over a vehicle component to be wrapped;a fixture configured to secure the vehicle component such that an exterior portion of the vehicle component faces the film; andan actuator coupled to the fixture and configured to controllably push the vehicle component into the film until the exterior portion is at least partially wrapped therein.2. The apparatus of claim 1 , wherein the grabber arm is coupled to a tension roller at a second end and is configured to grab and position the length of film using the tension roller.3. The apparatus of claim 1 , wherein the grabber arm is configured to position the length of film using an arc-like motion over the vehicle component prior to the actuator pushing the vehicle component upward.4. The apparatus of claim 1 , wherein the grabber arm is further configured to apply a desired tension between ends of the length of film.5. The apparatus of claim 1 , wherein the grabber arm is configured to remove backing from a side of the length of film facing the exterior portion of the vehicle component.6. The apparatus of claim 1 , further comprising a member including at least one roller arranged at an end thereof claim 1 , the member positioned ...

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 ...

METHODS AND APPARATUSES FOR UNIVERSAL INTERFACE BETWEEN PARTS IN TRANSPORT STRUCTURES

Techniques for providing universal interfaces between parts of a transport structure are disclosed. In one aspect of the disclosure, an apparatus for joining first and second parts of a transport structure includes an additively manufactured body having first and second surfaces. The first surface may connect to a first part such as, for example, a panel. The second surface may include a fitting for mating with a complementary fitting on a second part. 1. An apparatus for joining parts of a transport structure , comprising: a first surface for connecting to the first part, and', 'a second surface comprising a fitting for mating with a complementary fitting disposed on a second part., 'an additively manufactured body configured to be co-molded with a first part and including'}2. The apparatus of claim 1 , wherein the first surface is shaped to conform to a surface of the first part.3. The apparatus of claim 1 , wherein the first part comprises a panel.4. The apparatus of claim 1 , wherein the second part comprises a node.5. The apparatus of claim 1 , wherein the first surface is arranged substantially opposite the second surface.6. The apparatus of claim 1 , wherein the first surface comprises a porous material.7. The apparatus of claim 1 , wherein the fitting comprises a ball receptacle or a socket for a ball receptacle.8. The apparatus of claim 1 , wherein the fitting comprises a mounting plate or a receptacle for a mounting plate.9. The apparatus of claim 1 , wherein the fitting comprises a co-printed floating nut.10. The apparatus of claim 1 , wherein the fitting comprises one or more flex legs.11. The apparatus of claim 1 , wherein the fitting comprises one of a three-way location or a four-way location.12. An additively manufactured node for a transport structure claim 1 , comprising:a joint member configured to provide at least one structural connection; andan extended structure coupled to the joint member and comprising a fitting for connecting to a ...

INTEGRATED UPRIGHT AND DRIVE ELEMENTS

Integration of drive elements with an unsprung structure is disclosed. In one aspect of the disclosure, a motor includes a stator configured to mount to an unsprung structure of a wheeled vehicle through at least a damper or a spring. The motor further includes a rotor configured to drive a wheel of the vehicle. 1. A motor , comprising:a stator configured to mount to an unsprung structure of a wheeled vehicle through at least a damper or a spring; anda rotor configured to drive a wheel of the vehicle.2. The motor of claim 1 , wherein the stator is further configured to mount to the unsprung structure through a swing arm.3. The motor of claim 2 , further comprising a first gear coupled to the rotor claim 2 , the first gear having a first radius claim 2 , wherein a first gear is configured to mesh with a second gear claim 2 , the second gear having a second radius claim 2 , wherein a length of the swing arm is approximately equal to the sum of the first radius and the second radius claim 2 , such that the first gear and the second gear remain meshed when the stator swings in an arc of the swing arm.4. The motor of claim 1 , wherein the rotor is further configured to couple to the wheel through a speed reducer.5. The motor of claim 4 , further comprising:a first gear coupled to the rotor, wherein the first gear is configured to mesh with a second gear of the speed reducer.6. The motor of claim 1 , further comprising:a housing, wherein the stator is configured to be mounted to the unsprung structure through the housing.7. The motor of claim 1 , wherein the unsprung structure includes an upright.8. The motor of claim 1 , wherein the unsprung structure includes a hollow portion claim 1 , and the stator is configured to be mounted inside the hollow portion through at least the damper or the spring.9. The motor of claim 1 , wherein the stator is configured to be mounted to an outside of the unsprung structure.10. A system for a vehicle comprising:an unsprung structure ...

METHODS AND APPARATUS FOR MANUFACTURING OPTIMIZED PANELS AND OTHER COMPOSITE STRUCTURES

The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component. 1. A panel for use in a transport structure , comprising;at least one face sheet; andan additively manufactured (AM) core affixed to the at least one face sheet and optimized to provide a varying strength across at least a portion of the AM core for supporting expected load conditions determined across all three coordinate axes (x, y, z).2. The panel of claim 1 , wherein the at least one face sheet comprises a non-planar contour.3. The panel of claim 1 , wherein the at least one face sheet comprises a variable thickness.4. The panel of claim 1 , wherein the AM core comprises a homogenous material.5. The panel of claim 1 , wherein the AM core is optimized to provide a varying strength along a plurality of ...

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 UNIVERSAL INTERFACE BETWEEN PARTS IN TRANSPORT STRUCTURES

Techniques for providing universal interfaces between parts of a transport structure are disclosed. In one aspect of the disclosure, an apparatus for joining first and second parts of a transport structure includes an additively manufactured body having first and second surfaces. The first surface may connect to a first part such as, for example, a panel. The second surface may include a fitting for mating with a complementary fitting on a second part. 1. An apparatus for joining parts of a transport structure , comprising: a first surface for connecting to the first part, and', 'a second surface comprising a fitting for mating with a complementary fitting disposed on a second part., 'an additively manufactured body configured to be co-molded with a first part and including'}2. The apparatus of claim 1 , wherein the first surface is shaped to conform to a surface of the first part.3. The apparatus of claim 1 , wherein the first part comprises a panel.4. The apparatus of claim 1 , wherein the second part comprises a node.5. The apparatus of claim 1 , wherein the first surface is arranged substantially opposite the second surface.6. The apparatus of claim 1 , wherein the first surface comprises a porous material.7. The apparatus of claim 1 , wherein the fitting comprises a ball receptacle or a socket for a ball receptacle.8. The apparatus of claim 1 , wherein the fitting comprises a mounting plate or a receptacle for a mounting plate.9. The apparatus of claim 1 , wherein the fitting comprises a co-printed floating nut.10. The apparatus of claim 1 , wherein the fitting comprises one or more flex legs.11. The apparatus of claim 1 , wherein the fitting comprises one of a three-way location or a four-way location.12. An additively manufactured node for a transport structure claim 1 , comprising:a joint member configured to provide at least one structural connection; andan extended structure coupled to the joint member and comprising a fitting for connecting to a ...

METHODS FOR PRODUCING PANELS USING 3D-PRINTED TOOLING SHELLS

Techniques for producing panels such as for use in a vehicle, boat, aircraft or other transport structure or mechanical structure using a 3-D-printed tooling shell are disclosed. A 3-D printer may be used to produce a tooling shell containing Invar and/or some other material for use in molding the panels. A channel may be formed in a 3-D printed tooling shell for enabling resin infusion, vacuum generation or heat transfer. Alternatively, or in addition to, one or more hollow sections may be formed within the 3-D printed tooling shell for reducing a weight of the shell. The panel may be molded using the 3-D printed tooling shell. 1. A method of producing a composite panel for a transport or other mechanical structure using a three-dimensional (3-D) printed tooling shell comprising Invar , the method comprising:applying a composite material on a surface of the 3-D printed tooling shell; andforming the composite panel from the composite material using the 3-D printed tooling shell as a section of a mold.2. The method of claim 1 , further comprising:applying, over the composite material, a second 3-D printed tooling shell, the second 3-D printed tooling comprising a second section of the mold; andwherein the forming the composite panel comprises shaping the composite material disposed between the 3-D printed tooling shell and the second 3-D printed tooling shell.3. The method of claim 1 , wherein the composite panel comprises a composite body panel.4. The method of claim 1 , wherein the composite material comprises a carbon fiber composite material.5. The method of claim 4 , wherein the applying a composite material comprises applying one or more layers of carbon fiber using pre-impregnated carbon fiber plies.6. The method of claim 5 , wherein the applying a composite material further comprises applying resin to the one or more layers of the carbon fiber.7. The method of claim 1 , wherein the composite material comprises Carbon Fiber Reinforced Polymer (CFRP).8. The ...

Systems and methods for co-printed or concurrently assembled hinge structures

Systems and methods of co-printing a unitary hinge are provided. The unitary hinge may be co-printed using an additive manufacturing process. The unitary hinge includes a hinge pin that is substantially cylindrical in shape. The unitary hinge also includes a knuckle which surrounds a portion of the hinge pin and is configured to be manipulated about the hinge pin. The hinge pin is fabricated in situ with the knuckle such that further assembly is unnecessary. The unitary hinge may also include retention mechanism to retain the hinge within the knuckle without substantially restricting the knuckle from being rotated about the hinge pin. The unitary hinge may further be configured with a fluid port which may, for example, be used to provide a lubricant to an area between the hinge pin and the knuckle or to vacuum powder material or debris from the area.

ROBOTIC ASSEMBLY OF TRANSPORT STRUCTURES USING ON-SITE ADDITIVE MANUFACTURING

Techniques for flexible, on-site additive manufacturing of components or portions thereof for transport structures are disclosed. An automated assembly system for a transport structure may include a plurality of automated constructors to assemble the transport structure. In one aspect, the assembly system may span the full vertically integrated production process, from powder production to recycling. At least some of the automated constructors are able to move in an automated fashion between the station under the guidance of a control system. A first of the automated constructors may include a 3-D printer to print at least a portion of a component and to transfer the component to a second one of the automated constructors for installation during the assembly of the transport structure. The automated constructors may also be adapted to perform a variety of different tasks utilizing sensors for enabling machine-learning. 1. An automated assembly system for a transport structure , comprising:a plurality of automated constructors to manufacture and assemble the transport structure, wherein a first one of the automated constructors comprises a three-dimensional (3-D) printer to print at least a portion of a component and transfer the component to a second one of the automated constructors for installation during the assembly of the transport structure.2. The automated assembly system of claim 1 , wherein at least some of the plurality of automated constructors are configured to move in an automated fashion between stations under the guidance of a control system.3. The automated assembly system of claim 1 , wherein at least some of the plurality of automated constructors comprise one or more sensors configured to respectively enable each of the at least some of the plurality of automated constructors to adaptively perform one or more machine-learning functions.4. The automated assembly system of claim 3 , wherein the one or more machine-learning functions comprise at ...

ADDITIVELY MANUFACTURED STRUCTURES FOR VEHICLE DOORS

Techniques for using additively manufactured structures for doors are disclosed. These structures may include complex features and interfaces to enable connections to various systems in a door. The AM structure can include fasteners, hinges, hinge attachments and other structures which can advantageously be printed with the AM door structures. 1. A door structure , comprising:at least one additively manufactured (AM) section;a plurality of sections coupled together at least in part by respective adhesive bonds, wherein the AM section is optimized to meet strength to weight performance metrics.2. The door structure of claim 1 , further comprising an AM reinforcement configured to have a smaller strength-to-size ratio than conventionally built components.3. The door structure of claim 1 , wherein the plurality of sections are 3-D printed.4. The door structure of claim 1 , further comprising a plurality of AM mechanical reinforcements in positions requiring them.5. The door structure of claim 1 , further comprising one or more co-printed crash beams integrated at mounting points of the at least one AM section.6. The door structure of claim 1 , further including one or more fastener claim 1 , hinge claim 1 , or hinge attachment co-printed with the at least one AM section.7. A door for a vehicle or a mechanized assembly claim 1 , comprising:a plurality of additively manufactured (AM) structures configured to reinforce a corresponding plurality of modular sections; anda plurality of functional sections.8. The door of claim 7 , further comprising a mirror mount section.9. The door of claim 7 , further comprising a grab handle section.10. The door of claim 7 , further comprising a latch section for coupling the door to a vehicle frame.11. The door of claim 7 , further comprising a glass drop motor section.12. The door of claim 7 , further comprising a hinge section.13. The door of claim 7 , further comprising a regulator section.14. A method for manufacturing a door for a ...

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

Methods and apparatus for manufacturing optimized panels and other composite structures

The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component.

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 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.

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

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.

Additively manufactured structures for vehicle doors

Techniques for using additively manufactured structures for doors are disclosed. These structures may include complex features and interfaces to enable connections to various systems in a door. The AM structure can include fasteners, hinges, hinge attachments and other structures which can advantageously be printed with the AM door structures.

Methods and apparatuses for universal interface between parts in transport structures

Techniques for providing universal interfaces between parts of a transport structure are disclosed. In one aspect of the disclosure, an apparatus for joining first and second parts of a transport structure includes an additively manufactured body having first and second surfaces. The first surface may connect to a first part such as, for example, a panel. The second surface may include a fitting for mating with a complementary fitting on a second part.

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

Methods and apparatuses for universal interface between parts in transport 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.

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

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.

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.

Additively manufactured structures for vehicle doors

Additively manufactured structures for vehicle doors

Techniques for using additively manufactured structures for doors are disclosed. These structures may include complex features and interfaces to enable connections to various systems in a door. The AM structure can include fasteners, hinges, hinge attachments and other structures which can advantageously be printed with the AM door structures.

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.

Integrated upright and drive elements

Integration of drive elements with an unsprung structure is disclosed. In one aspect of the disclosure, a motor includes a stator configured to mount to an unsprung structure of a wheeled vehicle through at least a damper or a spring. The motor further includes a rotor configured to drive a wheel of the vehicle.

Integrated upright and drive elements

Integration of drive elements with an unsprung structure is disclosed. In one aspect of the disclosure, a motor includes a stator configured to mount to an unsprung structure of a wheeled vehicle through at least a damper or a spring. The motor further includes a rotor configured to drive a wheel of the vehicle.

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.

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.

Methods and apparatuses for universal interface between parts in transport structures

Techniques for providing universal interfaces between parts of a transport structure are disclosed. In one aspect of the disclosure, an apparatus for joining first and second parts of a transport structure includes an additively manufactured body having first and second surfaces. The first surface may connect to a first part such as, for example, a panel. The second surface may include a fitting for mating with a complementary fitting on a second part.

Apparatus and methods for connecting nodes to panels in transport structures

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.

現場付加製造を使用する輸送構造物のロボット組み立て

【課題】輸送構造物の構成要素またはその一部の柔軟な現場付加製造のための手法を提供する。【解決手段】輸送構造物の自動組み立てシステムは、輸送構造物を組み立てるための複数の自動コンストラクタ６２００を含む。組み立てシステムは、粉末製造から再生利用まで完全に垂直的に統合された製造工程に広がる。複数の自動コンストラクタ６２００のうちの少なくとも一部が、制御システムの誘導の下で自動化された方法でステーション６１００間を移動することができる。複数の自動コンストラクタ６２００のうちの第１の自動コンストラクタ６２００が、構成要素の少なくとも一部をプリントし、その構成要素を複数の自動コンストラクタ６２００のうちの第２の自動コンストラクタ６２００に移動し輸送構造物の組み立て中に取り付ける、３－Ｄプリンタを含む。自動コンストラクタ６２００は、機械学習を可能にするためにセンサーを利用して多種多様な作業を実行する。【選択図】図６

Systems and methods for co-printed or concurrently produced hinge structures

Systems and methods of co-printing a unitary hinge are provided. The unitary hinge may be co-printed using an additive manufacturing process. The unitary hinge includes a hinge pin that is substantially cylindrical in shape. The unitary hinge also includes a knuckle which surrounds a portion of the hinge pin and is configured to be manipulated about the hinge pin. The hinge pin is fabricated in situ with the knuckle such that further assembly is unnecessary. The unitary hinge may also include retention mechanism to retain the hinge within the knuckle without substantially restricting the knuckle from being rotated about the hinge pin. The unitary hinge may further be configured with a fluid port which may, for example, be used to provide a lubricant to an area between the hinge pin and the knuckle or to vacuum powder material or debris from the area.

Methods and apparatuses for universal interface between parts in transport structures

Techniques for providing universal interfaces between parts of a transport structure are disclosed. In one aspect of the disclosure, an apparatus for joining first and second parts of a transport structure includes an additively manufactured body having first and second surfaces. The first surface may connect to a first part such as, for example, a panel. The second surface may include a fitting for mating with a complementary fitting on a second part.

Integrated upright and drive elements