Abstract: Systems, apparatus, and method for manufacturing are disclosed. In an aspect, the apparatus may be a cold-spray nozzle. The cold-spray nozzle may include a variable diameter convergent part. The cold-spray nozzle may also include a variable diameter divergent part. The variable diameter divergent part may form a diffuser. Additionally, The cold-spray nozzle may include a ring portion. The ring portion may couple the variable diameter convergent part and the variable diameter divergent part. Additionally, the ring portion may control the opening to the diffuser.

Abstract: Techniques for optimizing powder hole removal are disclosed. In one aspect, an apparatus for inserting powder removal features may identify what powder removal features are optimal for a given AM component, as well as the optimal location and physical characteristics of these features. The features are automatedly added to the component, and an FEA test is run. In the event of failure, the offending feature is removed and the process is repeated. If successful then the loose powder may be removed in a post-processing step following AM.

Abstract: Systems, apparatus, and method for manufacturing a structure are disclosed. The structure includes a first portion, a second portion, and a structural joint. The apparatus is configured to receive instructions for printing the structural joint. The instructions are based on a data model of the structural joint. The apparatus is also configured to receive the first portion and the second portion, the first portion having a first conical tip and the second portion having a second conical tip. The apparatus is further configured to receive material. Additionally, the apparatus is configured to print the structural joint based on the instructions. The printing may include spray forming the material to produce the structural joint. The structural joint connects the first portion to the second portion.

Abstract: One aspect is an apparatus including a first node including a first bonding surface and a second node including a second bonding surface. The apparatus includes a feature configured to accept an adhesive and an adhesive channel coupled to the feature configured to accept the adhesive. The apparatus includes a shear joint coupling the first node and the second node, the shear joint configured to receive the adhesive in an adhesive region formed by the first bonding surface and the second bonding surface, the adhesive for coupling the first bonding surface to the second bonding surface through the feature configured to accept the adhesive.

Abstract: 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.

Abstract: Manufacturing cell based vehicle manufacturing systems and methods for a wide variety of vehicles are disclosed. In one aspect, a manufacturing cell configured for assembling a frame of a vehicle is disclosed. The manufacturing cell includes a positioner, a robot carrier and a robot. The positioner is configured to receive a fixture table configured to hold the frame. The robot carrier includes a vertical lift. The robot is configured to assemble the frame. The positioner is configured to support the frame in a vertical position during an assembling process. In another aspect of the disclosure, a system for manufacturing a vehicle based on a manufacturing cell is disclosed. In another aspect of the disclosure, a method for manufacturing a vehicle based on a manufacturing cell is disclosed.

Abstract: 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.

Abstract: Systems and methods of adapting the geometrical shape of a laser beam in laser-based powder-bed fusion (PBF) are provided. An apparatus for laser-based powder-bed fusion includes a depositor that deposits a plurality of layers of a powder material. The apparatus further includes a laser beam source that generates a laser beam having a variable beam geometry. A laser application component applies the laser beam in one of a plurality of beam geometries to fuse the powder material to construct a build piece.

Abstract: An additively manufactured node is disclosed. A node is an additively manufactured (AM) structure that includes a feature, e.g., a socket, a channel, etc., for accepting another structure, e.g., a tube, a panel, etc. The node can include a node surface of a receptacle extending into the node. The receptacle can receive a structure, and a seal interface on the node surface can seat a seal member between the node surface and the structure to create an adhesive region between the node and the structure, the adhesive region being bounded by the node surface, the structure, and the seal member. The node can also include two channels connecting an exterior surface of the node to the adhesive region. In this way, adhesive can be injected into the adhesive region between the node and the structure, and the adhesive can be contained by the seal member.

Abstract: Wishbone-style control arm assemblies for a vehicle and methods for assembling the same are disclosed. A control arm assembly includes a first elongated segment having a first connection feature at one end of the first segment. The control arm assembly includes a second elongated segment having a second connection feature at one end of the second segment. Opposite longitudinal ends of the first and second segments may include third and fourth connection features, respectively, that are configured to interface with the vehicle. The first and second connection features are aligned to form an aperture that extends at least partially through the first and segment connection features, through which a bushing is press-fit and then swaged to form a strong connection that reduces or eliminates the need for mechanical fasteners or adhesive bonds.

Abstract: A metal extrusion and nodes based structure is provided. The structure comprises one or more arc members connected by one or more node members, wherein the arc comprises (i) a wing feature which is configured to mate with one or more non-structural components, (ii) an internal passage feature which is configured to be inserted into a connecting feature of the corresponding node member, and (iii) one or more keying features formed from a mating interface with the corresponding node member.

Abstract: Connections between nodes and tubes are provided. An apparatus can include additively manufactured first and second nodes, a tube, and an interconnect connecting the tube to the first and second nodes. An apparatus can include a node having an end portion with inner and outer concentric portions forming an annular gap therebetween, and a tube having an end portion extending into the gap.

Abstract: 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.

Abstract: Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node having a socket. The apparatus includes a panel interconnected with node. The panel includes opposing surface layers and a core between at least a portion of the surface layers. The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.

Abstract: Apparatus and methods for joining nodes to tubes with node to tube joints are presented herein. Joining techniques allow the connection of additively manufactured nodes to tubes. In an embodiment, at least one node may be joined to a tube and may be a part of a vehicle chassis. The node to tube joint connection incorporates adhesive bonding between the node to tube to realize the connection. Sealants may be used to provide sealed regions for adhesive injection, which are housed in sealing interfaces co-printed with the additively manufactured nodes. Additionally, seals may act as isolators and reduce galvanic corrosion.

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: 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.

Abstract: An end effector for interfacing with a nozzle is disclosed. The end effector comprises a first end, which includes a receptacle. The end effector comprises one or more retention features positioned along a perimeter of the receptacle, where each of the one or more retention features is movable between a first position and a second position. Each of the one or more retention features is configured to lock the nozzle by securing onto a corresponding one of the one or more nozzle retention features in the first position, and to release the nozzle in the second position. The end effector may further comprise one or more actuators and a first channel, which includes a first inlet and a first outlet. A method of using an end effector to interface with a nozzle is also disclosed.

Abstract: Apparatus and methods for additively manufacturing microtube heat exchangers are disclosed herein. A heat exchanger header is additively manufactured with high density microtube arrays to achieve an integrated structure achieving values of heat transfer effectiveness Eff up to ninety percent and values of transfer surface area densities up to 20,000 m2/m3. The heat exchanger header can be printed with a high density microtube array to separate different types of fluids or liquids into different microtubes and to form a high quality seal. Additionally, microtubes and/or microtube arrays can be additively manufactured to be curved or to have pleats; and microtube lattice arrays can be compactly positioned within hollow support structures.

Abstract: Apparatus and methods for sealing powder holes in additively manufactured parts are presented herein. Powder holes are co-printed to facilitate post processing sealing. Embodiments include co-printed caps, friction welded caps, rivets, silicone plugs, co-printed tangs, multiple micro holes, layup, and spin forming. By using one or more of the above techniques, powder holes can be sealed on additively manufactured parts.