Abstract: According to some configurations of the present disclosure, an alloy may include a composition that includes magnesium (Mg) that is approximately 5 to 12% by weight of the composition; manganese (Mn) that is approximately 0.1 to 2% by weight of the composition; and silicon (Si) that is approximately 0.3 to 3% by weight of the composition; and aluminum (Al) that is a balance of the composition. In one configuration, the composition may further include one or more of iron (Fe), titanium (Ti), zirconium (Zr), chromium (Cr), and/or yttrium (Y).

Abstract: Alloy materials and three-dimensional (3-D) printed alloys are disclosed. An alloy in accordance with an aspect of the present disclosure comprises aluminum, magnesium, and silicon wherein a composition of the alloy comprises from at least 5 percent (%) by weight to 20% by weight of silicon and from at least 7% by weight to 10% by weight of magnesium.

Abstract: Integrated vehicle structures are provided herein. An integrated vehicle structure can include an enclosure portion configured to house an electric motor and a plurality of extended portions extending from the enclosure portion. The enclosure portion and the plurality of extended portions can be load-bearing and configured to bear vehicle loads. The extended portions of the integrated vehicle structures can include a connection portion configured to connect with another load-bearing structure to at least receive or transmit loads. The plurality of extended portions can be configured to transfer vehicle loads along physically separate paths. A portion of the enclosure portion can define an opening configured to allow a drive shaft to connect the electric motor to a wheel. The enclosure portion can be configured with an opening for allowing the installation and removal of the electric motor.

Abstract: Techniques for dehumidifying powder used as print material in a powder bed fusion (PBF) three-dimensional (3-D) system are disclosed. A hopper includes one or more ultrasonic transducers (UTs) positioned at strategic locations. When activated, the UTs use sound pressure at ultrasonic frequencies to agitate the powder particles held in the hopper. The movement of the particles drives moisture trapped between the particles into one or more desiccants. In various embodiments, the desiccants may be supported by desiccators suspended in the powder, such as via the casing of the hopper. In other embodiments, the desiccants may be desiccant bags provided in a desiccant insert. The moisture accumulates in the desiccants. Among other advantages, no separate thermal source is needed to dry the powder, which can be provided directly to the PBF 3-D system via the re-coater for depositing layers to form a build piece.

Abstract: An approach to positioning one or more robotic arms in an assembly system may be described herein. For example, a system for robotic assembly may include a first robot, a second robot, and a control unit. The control unit may be configured to receive a first target location proximal to a second target location. The locations may indicate where the robots are to position the features. The control unit may be configured to calculate a first calculated location of the first feature of the first subcomponent, measure a first measured location of the first feature of the first subcomponent, determine a first transformation matrix between the first calculated location and the first measured location, reposition the first feature of the first subcomponent to the first target location using the first robot, the repositioning based on the first transformation matrix.

Abstract: Techniques for modeling a part with a complex geometric feature (CGF) for use with a three-dimension (3-D) printer are disclosed. In one aspect of the disclosure, a method of modeling a part for 3-D printing includes determining a first volume of the part. The first volume may be modeled using a 3-D computer-aided design (CAD) model. A second volume of the part is determined. The CGF may be modeled within the second volume using parametric modeling based on 3-D printing parameters.

Abstract: Having a flexible robotic system layout that allows for the assembly of any structure creates a challenge in finding an optimal sequence of assembly. In some examples, the optimal sequence of assembly may provide the highest robot utilization, the shortest cycle time, the greatest assembly accuracy of the final assembly, or any combination thereof. The processing system disclosed herein may be configured to generate assembly sequences for a plurality of parts and determine an optimal assembly sequence from the generated assembly sequences by comparing the generated assembly sequences.

Abstract: One aspect is an apparatus including a plurality of additively manufactured components each having an adhesive injection channel. The components are connected together such that adhesive injection channels are aligned to form an adhesive path that allows adhesive flow between the components. Another aspect is an apparatus, including an additively manufactured component having an adhesive injection channel and an adhesive flow mechanism comprising at least one of an adhesive side end effector or a vacuum side end effector, the adhesive flow mechanism configured to provide adhesive to the adhesive injection channels.

Abstract: Methods and apparatuses for assembling components are described. An apparatus in accordance with an aspect of the present disclosure comprises a first structure having a first tongue, a second tongue, and a third tongue, the second tongue being between the first tongue and the third tongue, a second structure having a first groove, a second groove, and a third groove, the second groove being between the first groove and the third groove, a first adhesive, coupled to the first tongue and the first groove and coupled to the third tongue and the third groove when the first structure is coupled to the second structure, and a second adhesive coupled to the second tongue and the second groove when the first structure is coupled to the second structure, wherein the first adhesive is injected into the first groove and the third groove and the second adhesive is injected into the second groove.

Abstract: A computing system may direct a first robotic arm to a first position based on a first set of coordinates. The computing system may cause the first robotic arm to engage with a first structure based on the first position of the first robotic arm. Further, the computing system may direct the first robotic arm to a second position based on a second set of coordinates such that the first structure is brought within a joining proximity of a second structure without a fixture retaining the first structure and without a fixture retaining the second structure, wherein the first structure is configured to be joined with the second structure when the first and second structures are within the joining proximity, the joining proximity being a proximity at which the first and second structures can be joined together.

Abstract: Apparatus and methods for removing and/or destroying support structures associated with objects fabricated using additive manufacturing techniques are presented herein. Structural supports may be used during an additive manufacturing process to prevent deformation of a build piece (e.g., three dimensional (3D) printed structure). In some examples, a build piece may be manufactured such that the structural supports are internal to the completed build piece. However, removing the structural supports may reduce the weight of the build piece and reduce the amount of debris trapped within the build piece. Thus, certain aspects of the disclosure are directed to a hose including a bendable and elongated tube member as well as a fracturing member configured to fracture an internal support structure within an additively manufactured part.

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

Abstract: Techniques for co-printing of bus bars for printed structural energy modules are presented herein. An apparatus in accordance with an aspect of the present disclosure comprises a first component configured to be a primary structure of a vehicle, the first component-co-printed with a first electrical conductive path, the first electrical conductive path configured to be connected to a second electrical conductive path of a second component of the vehicle, wherein the first electrical conductive path and the second electrical conductive path are configured to enable electricity transmission.

Abstract: Techniques for rapid powder removal in a 3-D printer are disclosed. In various embodiments, the 3-D printer has a build plate for supporting a build piece. The build plate includes first structures for supporting unfused powder on a top of the build plate when the first structures are in a closed configuration. The first structures can transition to an open configuration to expose paths for allowing the unfused powder to pass through the build plate, and a second structure for preventing the build piece from passing through the build plate when the first structures are in the open configuration. In various embodiments, the unfused powder can thereafter be replaced with cool powder to assist in forming a predictable microstructure that makes up the build piece.

Abstract: Aspects for implementing 3-D printed metrology feature geometries and detection are disclosed. The apparatus may a measurement device for a 3-D printed component. The component may include a plurality of printed-in metrology features arranged at different feature locations on a surface of the component. The measurement device can be configured to detect the feature locations of the printed-in metrology features and to determine a position or an orientation of the component based on the detected feature locations. In various embodiments, the metrology feature may be a protruding or recessed spherical portion, with the corresponding feature location at the center of the sphere.

Abstract: This disclosure describes an additive manufacturing method that includes monitoring a temperature of a portion of a build plane during an additive manufacturing operation using a temperature sensor as a heat source passes through the portion of the build plane; detecting a peak temperature associated with one or more passes of the heat source through the portion of the build plane; determining a threshold temperature by reducing the peak temperature by a predetermined amount; identifying a time interval during which the monitored temperature exceeds the threshold temperature; identifying, using the time interval, a change in manufacturing conditions likely to result in a manufacturing defect; and changing a process parameter of the heat source in response to the change in manufacturing conditions.

Abstract: An additive manufacturing system comprises a build plane and an energy source configured to direct energy onto a work region of the build plane. An optical detector is configured to receive one or more optical signals from the work region. An optical filter is positioned between the work region and the optical detector, wherein the optical filter includes a first partially transmissive polarized filter having a first polarization axis and a second partially transmissive polarized filter having a second polarization axis. The first polarization axis is rotationally offset from the second polarization axis approximately 90 degrees. The optical filter improves the signal to noise ratio of the optical sensors.

Abstract: Multifunction noise suppression and crash structures are disclosed. In one aspect of the disclosure, the multifunction structure includes a body, inlet and outlet pipes, and a plurality of walls within the body that bound resonator cells and that are configured to suppress exhaust noise passing through the resonator cells from the inlet to the outlet pipes. The structure may be positioned between crash rails at the rear of the vehicle and between the engine and bumper. The walls may be generally aligned with, or near, the predicted impact direction and they may crumple in a controlled manner during an impact. In various embodiments the structure is 3D printed to enable construction of a wide diversity of geometric topologies and to minimize mass.

Abstract: Aspects are provided relating to additive manufacturing. In one aspect, an apparatus for producing a three-dimensional (3D) structure is described that includes a build chamber having a top portion with windows through which radiative energy from one or more sources is provided to the build chamber to produce the 3D structure, and one or more manifolds disposed within the build chamber. The manifolds are configured to perform a gas exchange within the build chamber, and each manifold is positioned above a region where envelopes of radiative energy from the one or more sources overlap. In another aspect, the manifolds are moved to a first position adjacent to the top portion of the build chamber during a first mode of operation and moved to a second position away from the top portion of the build chamber during a second mode of operation.

Abstract: A multi-material three-dimensional (3-D) powder bed fusion-based (PBF) printer is disclosed. In one aspect, the 3-D PBF includes a body, a controller coupled to the body, a plurality of cartridges coupled to a print nozzle, an energy source coupled to an upper surface of the body, a deflector for deflecting an energy beam from the energy source, and a build plate on which a build piece can be 3-D printed. Each cartridge may include a slurry in which a specific print material or alloy is suspended. A depositor may selectively deposit the slurry onto the build plate to form a plurality of consecutive layers. For a given layer or a given region thereof, the controller may selectively deposit different amounts of the slurry to produce an alloy having a desired composition. A heating element may be used to vaporize the solvent in the deposited slurry. Using the deflector, the energy source can fuse the regions to sinter the deposited material and in some embodiments, to vaporize the solvent prior to sintering.