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: 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: 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: 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: Techniques for structurally integrated heat exchangers are presented herein. A heat exchanger in accordance with an aspect of the present disclosure comprises a structure configured to enclose a volume for storing a first fluid, and to connect to a load. The heat exchanger further comprises a first and a second header first arranged in opposing inner walls of the structure. The heat exchanger further comprises one or more load-bearing struts extending to connect the first and second headers within the volume and configured to pass a second fluid through the volume for transferring heat to the first fluid, the second fluid configured to cool a different component in the vehicle.

Abstract: Apparatus and methods for additively manufacturing adhesive inlet and outlet ports are presented herein. Adhesive inlet and outlet ports are additively manufactured to include additively manufactured (AM) valves for reducing and/or eliminating sealant leakage and backflow. Robot end effectors are tailored to interface with the AM inlet and outlet ports and to provide an adhesive source and/or a vacuum source. AM inlet and outlet ports enable robust, lightweight, multi-material AM parts connected via adhesive joining.

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: 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: Systems and methods for co-casting of additively manufactured, high precision Interface Nodes are disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. Co-casting of Interface Nodes by casting a part onto the Interface Node results in a hybrid structure comprising the cast part and the additively manufactured Interface Node. The interface node may include at least one of a node-to-tube connection, node-to-panel connection, or a node-to-extrusion connection. In an embodiment, engineered surfaces may be provided on the Interface Node to improve the blend between the Interface Node and the cast part during the co-casting process.

Abstract: A node may be additively manufactured. The node may include a first surface and a second surface, and the second surface may bound a recess of the node. A structure may be inserted into the recess. A sealing member extend away from the second surface and contact the structure, such that a sealed space may be created between the node and the structure. An adhesive may be applied in the sealed space to at least partially attach the structure to the node.

Abstract: Methods and apparatuses for energy unit cells for primary structures are described. The method comprises obtaining enclosure criteria of an enclosure space, wherein the enclosure space is configured to contain an energy storage device. The method further comprises obtaining a load case of a primary structure of a vehicle. The method further comprises determining a primary structure design based on the enclosure criteria and the load case, where the primary structure design incorporates the enclosure space.

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: Apparatuses and methods are provided for joining at least two structural components. A receiving structure including a mating profile having one or more tongues and grooves may be configured to contain at least one adhesive. A joint feature of a node structure may include a mating feature with a converging profile configured to mate with the mating profile of the receiving structure. One or more tongues and grooves may be present at the joint feature and configured to mate with corresponding tongues and grooves of the receiving structure.

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: 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: Apparatus and methods for joining tubes in transport structures are presented herein. A part having an attached node with a socket can be joined with tubes. The tubes can be placed along nonparallel axes within the socket; and a wedge can be used to secure the tubes to the socket. The wedge can be secured between the tubes by using a fastener, such as a blind fastener; alternatively, or additionally, the wedge can be secured between the tubes using an adhesive.

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.