Abstract: A thermo spray gun (10) includes at least one of; at least one removable nozzle tip (20) for spraying a coating material, at least one replaceable nozzle tip (20) for spraying a coating material, and at least one interchangeable nozzle tip (20) for spraying a coating material. A thermo spray gun system (1000) includes a thermal spray gun (10) and at least one mechanism (30/40) at least one of; storing at least one nozzle tip installable on the thermal spray gun and being structured and arranged to install at least one nozzle tip on the thermal spray gun. A method of coating a substrate (S) using a thermo spray gun (10) includes mounting at least one nozzle tip (20) on the thermo spray gun (10) and spraying a coating material with the at least one nozzle tip (20).

Abstract: In an embodiment, a maneuverable capture device includes a frame, a plurality of rotors secured to the frame, an attachment point disposed on the frame for securing a cable of a carrier aircraft to the frame, and an attachment feature configured to secure maneuverable capture device to a dock of a parasite aircraft. In an embodiment, a method of docking a maneuverable capture device with a parasite aircraft includes positioning a carrier aircraft above a parasite aircraft, releasing the maneuverable capture device attached to the carrier aircraft by a cable from the carrier aircraft, flying the maneuverable capture device to a dock of the parasite aircraft, and securing the maneuverable capture device to the dock of the parasite aircraft.

Abstract: An inertia weight assembly positionable within a receiving portion of a rotor blade for use on a rotorcraft. The inertia weight assembly includes a weighted core and a casing having a closed outboard end and forming a cavity. The weighted core is disposed in the cavity such that the casing at least partially encloses the weighted core. The weighted core is formed from a first material and the casing is formed from a second material that is dissimilar to the first material. The casing provides an interface between the weighted core and the receiving portion of the rotor blade. The second material is more bondable to the receiving portion of the rotor blade than the first material.

Abstract: A propulsion assembly for a rotorcraft includes a blade assembly, a drive shaft coupled to the blade assembly and an electric motor coupled to the drive shaft and operable to provide rotational energy to the drive shaft to rotate the blade assembly. The propulsion assembly includes a landing assistance turbine coupled to the drive shaft and operable to selectively provide rotational energy to the drive shaft during an underpowered descent to rotate the blade assembly and provide upward thrust, thereby reducing a descent rate of the rotorcraft prior to landing.

Abstract: An aircraft has multiple independent yaw authority mechanisms. The aircraft includes an airframe having first and second wings with at least first and second pylons extending therebetween and with a plurality of tail members extending therefrom each having an active control surface. A two-dimensional distributed thrust array is coupled to the airframe that includes a plurality of propulsion assemblies each having a rotor assembly and each operable for thrust vectoring. A flight control system is operable to independently control each of the propulsion assemblies. A first yaw authority mechanism includes differential speed control of rotor assemblies rotating clockwise compared to rotor assemblies rotating counterclockwise. A second yaw authority mechanism includes differential longitudinal control surface maneuvers of control surfaces of two symmetrically disposed tail members. A third yaw authority mechanism includes differential thrust vectoring of propulsion assemblies.

Abstract: An aircraft has an airframe with a two-dimensional distributed thrust array attached thereto having a plurality of propulsion assemblies that are independently controlled by a flight control system. Each propulsion assembly includes a housing with a gimbal coupled thereto that is operable to tilt about first and second axes responsive to first and second actuators. A propulsion system is coupled to and operable to tilt with the gimbal. The propulsion system includes an electric motor having an output drive and a rotor assembly having a plurality of rotor blades that rotate in a rotational plane to generate thrust having a thrust vector. Responsive to a thrust vector error of a first propulsion assembly, the flight control system commands at least a second propulsion assembly, that is symmetrically disposed relative to the first propulsion assembly, to counteract the thrust vector error, thereby providing redundant directional control for the aircraft.

Abstract: Systems and methods include providing vertical takeoff and landing (VTOL) aircraft with a cargo pod having a selectively inflatable bladder system that firmly secures a payload disposed within the cargo pod when the bladder system is pressurized. The bladder system also controls the location, position, and/or orientation of the payload in order to adjust, control, and/or maintain the center of gravity of the aircraft during flight. The aircraft includes an impact protection system that further pressurizes the bladder system to protect the payload and/or that disperses a flame-retardant fluid into the cargo pod to protect electrical components of the aircraft. The aircraft is fully autonomous and self-directed via a preprogrammed location-based guidance system to allow for accurate delivery of the payload to its intended destination. The bladder system is depressurized in response to a landing event to allow for e f the payload from the cargo pod.

Abstract: A propulsion assembly for a rotorcraft includes a blade assembly, a drive shaft coupled to the blade assembly and an electric motor coupled to the drive shaft and operable to provide rotational energy to the drive shaft to rotate the blade assembly. The propulsion assembly includes a landing assistance turbine coupled to the drive shaft and operable to selectively provide rotational energy to the drive shaft during an underpowered descent to rotate the blade assembly and provide upward thrust, thereby reducing a descent rate of the rotorcraft prior to landing.

Abstract: An aircraft is operable to transition between thrust-borne lift in a VTOL orientation and wing-borne lift in a biplane orientation. The aircraft includes an airframe having first and second wings with first and second pylons extending therebetween forming a central region. A two-dimensional distributed thrust array and a flight control system are coupled to the airframe. A nose cone and an afterbody are each selectively coupled to the airframe. In a cargo delivery flight configuration, the nose cone and the afterbody are coupled to the airframe such that the nose cone and the afterbody each extend between the first and second wings and between first and second pylons to form a cargo enclosure with an aerodynamic outer shape. In a minimal drag flight configuration, the nose cone and the afterbody are not coupled to the airframe such that air passes through the central region during flight.

Abstract: An autonomous package delivery aircraft is operable to transition between thrust-borne lift in a VTOL orientation and wing-borne lift in a forward flight orientation. The aircraft includes an airframe with a distributed thrust array coupled thereto. A flight control system is operably associated with the distributed thrust array and is configured to independently control each of the propulsion assemblies of the distributed thrust array. A package delivery module is coupled to the airframe. In the VTOL orientation, a first pair of propulsion assemblies is forward of the package delivery module while a second pair of propulsion assemblies is aft of the package delivery module. In a forward flight orientation, the first pair of propulsion assemblies is below the package delivery module and the second pair of propulsion assemblies is above the package delivery module.

Abstract: An aircraft has an airframe with a distributed thrust array attached thereto that includes a plurality of propulsion assemblies each of which is independently controlled by a flight control system. Each propulsion assembly includes a housing with a single axis gimbal coupled thereto and operable to tilt about a single axis. A propulsion system is coupled to and operable to tilt with the gimbal. The propulsion system includes an electric motor having an output drive and a rotor assembly having a plurality of rotor blades that rotate in a rotational plane to generate thrust having a thrust vector with a direction. Actuation of each gimbal is operable to tilt the respective propulsion system including the electric motor and the rotor assembly relative to the airframe to change the rotational plane of the respective rotor assembly relative to the airframe, thereby controlling the direction of the respective thrust vector.

Abstract: An aircraft for capturing drones includes an airframe having a drone channel with first and second wings extending outboard thereof. A two-dimensional distributed thrust array includes a plurality of propulsion assemblies coupled to each of the first and second wings such that the rotor disc of each propulsion assembly is outboard of the drone channel. A flight control system is coupled to the airframe and is operable to independently control each of the propulsion assemblies. A mesh bag is coupled to the drone channel forming a drone capture net. The aircraft is configured to convert between thrust-borne lift in a VTOL orientation and wing-borne lift in a biplane orientation. The aircraft is also configured to overtake a drone during flight in the biplane orientation such that the drone passes through the drone channel into the mesh bag, thereby capturing the drone in the drone capture net.

Abstract: An aerial imaging aircraft operable to transition between thrust-borne lift in a VTOL orientation and wing-borne lift in a biplane orientation. The aircraft includes an airframe having first and second wings with first and second pylons coupled therebetween. A two-dimensional distributed thrust array is coupled to the airframe. The thrust array includes a plurality of propulsion assemblies each operable for variable speed and omnidirectional thrust vectoring. A payload is coupled to the airframe and includes an aerial imaging module. A flight control system is operable to independently control the speed and thrust vector of each of the propulsion assemblies such that in an inclined flight attitude, the flight control system is operable to maintain the orientation of the aerial imaging module toward a target while translating the aircraft, changing aircraft altitude and/or circling the target.

Abstract: An aircraft has an airframe with first and second wings having first and second pylons extending therebetween. A distributed propulsion system attached to the airframe includes at least first, second, third and fourth propulsion assemblies that are independently controlled by a flight control system. A pod assembly is coupled to the airframe. In a VTOL flight mode, the first and second propulsion assemblies are forward of the pod assembly and the third and fourth propulsion assemblies are aft of the pod assembly. In a forward flight mode, the first and second propulsion assemblies are below the pod assembly and the third and fourth propulsion assemblies are above the pod assembly. In both the VTOL and forward flight modes, the first and fourth propulsion assemblies generate thrust having a first direction while the second and third propulsion assemblies generate thrust having a second direction that is different from the first direction.

Abstract: A line-replaceable thrust module includes a nacelle configured to be mechanically connected to an anchoring location of an unmanned aerial vehicle (UAV), an electric motor coupled to the nacelle, an electric speed controller configured to control the speed of the electric motor and configured to be electrically connected to a communication network of the UAV, and a fuel cell system configured to produce electrical energy from an electrochemical reaction between hydrogen and oxygen. The fuel cell system includes a fuel cell, a hydrogen tank, a pressure regulator coupled to the hydrogen tank, and a supply line coupled between the pressure regulator and the fuel cell.

Abstract: An aircraft includes an airframe and a distributed thrust array coupled to the airframe including at least six propulsion assemblies. A flight control system is operably associated with the distributed thrust array and is operable to independently control each of the propulsion assemblies. A package delivery module is coupled to the airframe. In a VTOL orientation utilizing thrust-borne lift, a first pair of propulsion assemblies is forward of the package delivery module, a second pair of propulsion assemblies is aft of the package delivery module and a third pair of propulsion assemblies is lateral of the package delivery module. In a forward flight orientation utilizing wing-borne lift, the first pair of propulsion assemblies is below the package delivery module, the second pair of propulsion assemblies is above the package delivery module and the third pair of propulsion assemblies is lateral of the package delivery module.

Abstract: An airframe for a tiltrotor aircraft includes a wing airframe including a rib, a fuselage airframe including a fore-aft overhead beam and a cradle support assembly. The cradle support assembly includes a forward wing support coupled to the fore-aft overhead beam and the wing airframe and an aft wing support coupled to the fore-aft overhead beam and the wing airframe. The rib, the fore-aft overhead beam, the forward wing support and the aft wing support are substantially aligned to form a wing-fuselage integrated airframe beam assembly to support the wing airframe.

Abstract: An aircraft has an airframe with a distributed thrust array attached thereto that includes a plurality of propulsion assemblies each of which is independently controlled by a flight control system. Each propulsion assembly includes a housing with a gimbal coupled thereto and operable to tilt about a single axis. A propulsion system is coupled to and operable to tilt with the gimbal. The propulsion system includes an electric motor having an output drive and a rotor assembly having a plurality of rotor blades that rotate in a rotational plane to generate thrust having a thrust vector with a magnitude in the longitudinal direction. Actuation of each gimbal is operable to tilt the respective propulsion system relative to the airframe in the longitudinal direction to change the rotational plane of the respective rotor assembly relative to the airframe, thereby controlling the magnitude of the respective thrust vector in the longitudinal direction.

Abstract: A propulsion assembly for an aircraft includes a housing having a gimbal coupled thereto that is operable to tilt about first and second axes. A propulsion system is coupled to and operable to tilt with the gimbal. The propulsion system includes an electric motor having an output drive and a rotor assembly having a plurality of rotor blades. The rotor assembly is rotatable with the output drive of the electric motor in a rotational plane to generate thrust having a thrust vector with a direction. The first axis of the gimbal is orthogonal to the second axis of the gimbal. Actuation of the gimbal tilts the propulsion system relative to the housing to change the rotational plane of the rotor assembly relative to the housing, thereby controlling the direction of the thrust vector within a thrust vector cone.

Abstract: An aircraft has an airframe with a two-dimensional distributed thrust array attached thereto having a plurality of propulsion assemblies that are independently controlled by a flight control system. Each propulsion assembly includes a housing with a gimbal coupled thereto that is operable to tilt about first and second axes responsive to first and second actuators. A propulsion system is coupled to and operable to tilt with the gimbal. The propulsion system includes an electric motor having an output drive and a rotor assembly having a plurality of rotor blades that rotate in a rotational plane to generate thrust having a thrust vector. Responsive to a thrust vector error of a first propulsion assembly, the flight control system commands at least a second propulsion assembly, that is symmetrically disposed relative to the first propulsion assembly, to counteract the thrust vector error, thereby providing redundant directional control for the aircraft.