Abstract: Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000° F. (1093° C.)) include forming precursor structures by additive manufacturing (“AM”) (e.g., “3D printing”) with a filament drawn from a spool. The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.

Abstract: Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000° F. (1093° C.)) include forming precursor structures by additive manufacturing (“AM”) (e.g., “3D printing”). The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.

Abstract: A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing a plurality of part layers in a consecutive manner on top of each other where each layer is deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are then inserted through the part layers to provide reinforcement of the part in the Z-direction. A plurality of additional part layers are deposited in a consecutive manner on top of each other on the part layers including the reinforcing Z-pins where each additional part layer is also deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are also inserted through the additional part layers to provide reinforcement of the part in the Z-direction.

Abstract: A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing a plurality of part layers in a consecutive manner on top of each other where each layer is deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are then inserted through the part layers to provide reinforcement of the part in the Z-direction. A plurality of additional part layers are deposited in a consecutive manner on top of each other on the part layers including the reinforcing Z-pins where each additional part layer is also deposited by laying down rows of filaments made of a thermoplastic composite material. Reinforcing Z-pins are also inserted through the additional part layers to provide reinforcement of the part in the Z-direction.

Abstract: An assembly formed by additive manufacturing comprises a top face sheet, a bottom face sheet, and a core structure between the top face sheet and the bottom face sheet, the core structure comprising a plurality of cells, wherein structural elements of the core structure defining the plurality of cells exhibit at least one electrical property in at least one direction varying from at least one electrical property in a second, different direction and at least one structural property in at least one direction varying from at least one structural property in a second, different direction, wherein at least a portion of the structural elements comprises a radar absorbing structure, the structural elements comprising a matrix material and at least one additive dispersed in or on the matrix material. Related radar absorbing structures and related methods of fabricating the radar absorbing structures are also disclosed.

Abstract: Methods for fabricating high-temperature composite structures (e.g., structures comprising carbon-carbon composite materials or ceramic composite matrix (CMC) materials and configured for use at temperature at or exceeding about 2000° F. (1093° C.)) include forming precursor structures by additive manufacturing (“AM”) (e.g., “3D printing). The precursor structures are exposed to high temperatures to pyrolyze a precursor matric material of the initial 3D printed structure. A liquid resin is used to impregnate the pyrolyzed structure, to densify the structure into a near-net final shape. Use of expensive and time-consuming molds and post-processing machining may be avoided. Large, unitary, integrally formed parts conducive for use in high-temperature environments may be formed using the methods of the disclosure.

Abstract: An assembly formed by additive manufacturing comprises a top face sheet, a bottom face sheet, and a core structure between the top face sheet and the bottom face sheet, the core structure comprising a plurality of cells, wherein structural elements of the core structure defining the plurality of cells exhibit at least one electrical property in at least one direction varying from at least one electrical property in a second, different direction and at least one structural property in at least one direction varying from at least one structural property in a second, different direction, wherein at least a portion of the structural elements comprises a radar absorbing structure, the structural elements comprising a matrix material and at least one additive dispersed in or on the matrix material. Related radar absorbing structures and related methods of fabricating the radar absorbing structures are also disclosed.

Abstract: A thrust-vectoring rocket motor nozzle includes a forward assembly having a forward shell with a flange configured for connection to a motor and a throat portion opposite the flange. A ball joint sleeve may be disposed proximate the throat portion, and an exit cone assembly may include a ball joint socket configured to mate with the ball joint sleeve to allow movement of the exit cone assembly about one or more axes relative to the forward assembly. A thermal barrier may be disposed in a gap between the forward assembly and the exit cone assembly. The forward assembly may include a throat insulator mechanically locked within the forward shell. Related methods include forming thrust-vectorable rocket motor nozzles. Rocket motors may include such nozzles.

Abstract: A thrust-vectoring rocket motor nozzle includes a forward assembly having a forward shell with a flange configured for connection to a motor and a throat portion opposite the flange. A ball joint sleeve may be disposed proximate the throat portion, and an exit cone assembly may include a ball joint socket configured to mate with the ball joint sleeve to allow movement of the exit cone assembly about one or more axes relative to the forward assembly. A thermal barrier may be disposed in a gap between the forward assembly and the exit cone assembly. The forward assembly may include a throat insulator mechanically locked within the forward shell. Related methods include forming thrust-vectorable rocket motor nozzles. Rocket motors may include such nozzles.

Abstract: The invention generally relates to turbines that efficiently process air or fluid flow while producing substantially no vibrational effects. In one embodiment, the invention provides a turbine including a rotatable shaft and three helical blades connected to the rotatable shaft, where each of the blades has a helical twist of about 360°.

Abstract: The invention generally relates to turbines that efficiently process air or fluid flow while producing substantially no vibrational effects. In certain embodiments, the invention provides a turbine including a rotatable shaft, and at least one blade connected to the rotatable shaft, in which the blade includes a helical shape and an angle of about 180° or greater.