Abstract: Aspects of methods, apparatuses, and computer-readable media for performing multi-material selection optimization (MMSO) to provide topologically and geometrically optimized multi-component structures (MCSs) across a plurality of design inputs and constraints are proposed. In some embodiments, a 3-D print model of an object based on load case criteria is obtained. A portion of the 3-D print model is determined that can be replaced with a commercial-off-the-shelf (COTS) part model such that the load case criteria remain satisfied. The portion or the 3-D print model can then be replaced with the COTS part model to determine the MCS model. In various embodiments, a mesh representation of the model can be generated, and plurality of optimization techniques can be used to determine the MCS model.

Abstract: This disclosure describes various methods and apparatus for characterizing an additive manufacturing process. A method for characterizing the additive manufacturing process can include generating scans of an energy source across a build plane; measuring an amount of energy radiated from the build plane during each of the scans using an optical sensor; determining an area of the build plane traversed during the scans; determining a thermal energy density for the area of the build plane traversed by the scans based upon the amount of energy radiated and the area of the build plane traversed by the scans; mapping the thermal energy density to one or more location of the build plane; determining that the thermal energy density is characterized by a density outside a range of density values; and thereafter, adjusting subsequent scans of the energy source across or proximate the one or more locations of the build plane.

Abstract: This invention teaches a multi-sensor quality inference system for additive manufacturing. This invention still further teaches a quality system that is capable of discerning and addressing three quality issues: i) process anomalies, or extreme unpredictable events uncorrelated to process inputs; ii) process variations, or difference between desired process parameters and actual operating conditions; and iii) material structure and properties, or the quality of the resultant material created by the Additive Manufacturing process. This invention further teaches experimental observations of the Additive Manufacturing process made only in a Lagrangian frame of reference. This invention even further teaches the use of the gathered sensor data to evaluate and control additive manufacturing operations in real time.

Abstract: A virtual railroad of vehicles is disclosed. In one aspect of the disclosure, a system includes one or more passenger vehicles of a peloton, and a first engine vehicle of the peloton. The first engine vehicle communicatively connected to the one or more passenger vehicles, wherein the first engine vehicle comprises: a processor communicatively connected to a memory and is configured to receive status information of the one or more passenger vehicles, determine, based on the received status information, a set of current values for a set of vehicle attributes for each of the one or more passenger vehicles, and adjust, based on the set of current values for the set of vehicle attributes, a position of a corresponding passenger vehicle of the one or more passenger vehicles.

Abstract: Self-supporting 3-D printed chassis structures are disclosed. Self-supporting ribs are selectively printed to walls of the structure to meet desired dynamic stiffness targets while maintaining a reduced mass. The self-supporting ribs can be used as both support structures (e.g., for outer walls) during 3-D printing and as stiffening structures when the chassis structure is in operation. In an embodiment, the chassis structure is printed such that no support structures are needed. Topology optimization can enable remaining unneeded internal ribs or supports to be removed, and a high inner spatial volume between ribs can be maintained to make maximum use of the part. In various embodiments, wall thicknesses can be maintained at or below 1-2 millimeters, which further reduces mass.

Abstract: 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.

Abstract: A three-dimensional (3-D) printer and technique for integrating additive and non-print manufacturing operations is disclosed. In an aspect, the 3-D printer includes an energy source and a powder bed regions for selectively fusing layers of a build piece. The 3-D printer further includes a robotic arm. The 3-D printing is interrupted responsive to instructions from a controller, upon which the robotic arm may perform one or more non-printing operations using the build piece such as milling, casting, molding, pressing, and the like. Following the non-printing operations, the 3-D printing operation continues, and a resulting assembly including the build piece is produced.

Abstract: Apparatuses and methods for in situ thermal treatment for PBF systems are provided. An apparatus for a PBF-based 3-D printer can include a heating element for heating a gas, wherein the heated gas is delivered via at least one port of the 3-D printer to conduct heat treatment on a build piece during printing. A method for thermal treatment in a PBF-based 3-D printer can include heating a gas and delivering it via at least one port of the 3-D printer arranged proximate a build piece to conduct heat treatment during printing. An apparatus for a PBF-based 3-D printer can include a temperature-regulating element for changing a temperature of a gas, at least one channel for delivering the gas to a plurality of ports, and a controller for determining gas temperatures and durations of application of the gas via different ones of the plurality of the ports.

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

Abstract: Techniques for joining nodes and subcomponents are presented herein. An apparatus in accordance with an aspect of the present disclosure comprises a 3-D printed first part having an interconnect co-printed with the first part such that the interconnect of the first part can float within the first part, and a 3-D printed second part having an interconnect co-printed with the second part such that the interconnect of the second part can float within the second part, wherein the interconnects of the first and second parts are configured to form a connection between the first and second parts.

Abstract: Methods and apparatuses for identifying an additive manufacturing process for unused output material of an atomization process are described. The method comprises determining a set of characteristics of output material that is unused in a first additive manufacturing process. The method further comprises determining a respective set of parameters associated with respective input material of each of a set of other additive manufacturing processes. The method of further comprises identifying one of the set of other additive manufacturing processes that accepts the output material as input material based on the characteristics of the output material and based on respective sets of parameters.

Abstract: Retention features are provided for joining at least two structural components in a fixtureless assembly system. A first structure including a groove may be configured to contain at least one adhesive, and a second structure may include a tongue configured to contact the at least one adhesive to join the first and second structures. The first structure may also include at least one window that receives electromagnetic (EM) radiation from an EM radiation source into the groove. The at least one adhesive is configured to cure at a first rate upon exposure to one of time or heating, and the at least one adhesive is configured to cure at a second rate faster than the first rate upon exposure to the EM radiation.

Abstract: Systems and methods for rotational additive manufacturing are disclosed. An apparatus in accordance with an aspect of the present disclosure comprises a build floor, a depositor system configured to deposit a layer of powder onto the build floor, a motor system causing a rotational motion between the depositor system and the build floor, wherein the depositor system deposits the layer of powder during the rotational motion, a receptacle wall configured to contain the powder on the build floor, an energy beam source configured to apply an energy beam in an active area of the layer of powder to selectively fuse a portion of the powder in the active area to form a portion of a build piece and a gas flow system configured to provide a gas flow across the active area while the energy beam selectively fuses the portion of the layer of powder in the active area.

Abstract: 3-D build jobs having surrogate supports, 3-D printers using surrogate supports, and techniques to support vulnerable regions of build pieces using surrogate supports are disclosed. The surrogate supports are generated in a first material configuration and are offset via a gap from the vulnerable regions. The gap comprises a second material configuration, such as loose or partially fused powder on which the build piece can be supported during 3-D printing. In alternative embodiments, the gap instead includes thin manual ties or a solid body using material that is stronger but more amenable to breaking off without damaging the build piece. Post-processing steps are dramatically reduced as the surrogate supports and gaps facilitate virtually error-free separation from the build piece. In an embodiment, the surrogate supports include a support structure extending to a fixed base underneath, the fixed base being a build plate or a global surrogate.

Abstract: Part retention features are disclosed for securing additively manufactured (AM) parts or for securing an AM part with another component, such as a node, panel, tube, extrusion, and the like, while an adhesive is being applied and/or while the adhesive is undergoing expansion due to a subsequent curing process. The retention features described herein can be used in the context of one or more AM parts such that the elements used to house the retention features (e.g., grooves, apertures, elastic elements, etc.) can advantageously be co-printed with the AM part, thereby removing a manufacturing step. The retention features also can be made with flatter profiles than existing solutions, making the overall structure smaller and less cumbersome to assemble.

Abstract: 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.

Abstract: Techniques for joining nodes and subcomponents are presented herein. An additively manufactured first node or subcomponent has a groove. An additively manufactured second node or subcomponent has a tongue configured to extend into and mate with the groove to form a tongue-and-groove connection between the first and second node or subcomponent. In some aspects, the tongue-groove connection may extend substantially around a periphery of the node or subcomponent. In other aspects, a first subcomponent having a fluid pipe interface may be coupled via a tongue-groove connection to a second subcomponent having a fluid pipe interface, thereby enabling fluid to flow between subcomponents of the resulting integrated component.

Abstract: A node to panel interface structure for use in a transport structure such as a vehicle is disclosed. In an aspect, the node includes a base, first and second sides protruding from the base to form a recess for receiving a panel, ports for adhesive injection and/or vacuum generation, one or more adhesive regions disposed on a surface of each side adjacent the panel, and at least one channel coupled between the first and second ports and configured to fill the adhesive regions with an adhesive, the adhesive being cured to form a node-panel interface. The node may be additively manufactured. In an exemplary embodiment, the node may use sealant features for including sealants that border and define the adhesive regions, and that may hermetically seal the region before and after adhesive injection. In another embodiment, the node may include isolation features for including isolators for inhibiting galvanic corrosion.

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: Apparatus and methods for additive manufacturing with variable extruder profiles are described herein. An extruder print head with multiple nozzles placed at different angles allows for additional degrees of freedom to additively manufacture parts with complex shapes. In addition with the use of shape memory alloy materials, the diameter of one or more nozzles can be adjusted during the additive manufacturing process. This allows for independent control of the build resolution and of the build rate.