Abstract: A method to manufacture a ceramic foam filter includes: sintering a filter body to a temperature greater than a molten metal to be filtered through the body; creating multiple tortuous path channels extending through the filter body individually having a repeated and controlled passage geometry creating a continuously changing diameter and area of a flow path through the multiple tortuous path channels causing localized increases and decreases in molten metal flow rate through the multiple tortuous path channels; and applying a mixture of at least one ceramic powder and at least one binder using additive manufacturing to shape the filter body including the multiple tortuous path channels.

Abstract: An anti-submarining seat cushion for a vehicle includes a main body constructed of an anisotropic material. The anisotropic material includes a primary material including a primary stiffness and a plurality of inserts that are dispersed throughout the primary material. The plurality of inserts exert an axial compressive force in response to the main body of the anti-submarining seat cushion experiencing a submarining load, where the axial compressive force is exerted in a direction that opposes the submarining load to increase an overall stiffness of the main body in a direction that aligns with the submarining load.

Abstract: Systems and methods are provided for cleaning surfaces of a workpiece. The system includes a housing defining an enclosure, a holding structure within the enclosure that is configured to support a workpiece, a first powder removal device that is configured to propel a first media toward the holding structure such that the first media contacts the workpiece while the workpiece is supported by the holding structure, a first sensing device that is configured to detect surface characteristics of the workpiece while the workpiece is supported by the holding structure, and a controller configured to, by a processor: detect a powder material on a surface of the workpiece based on the surface characteristics, and selectively operate the first powder removal device to remove the powder material from the surface with the first media while the workpiece is supported by the holding structure.

Abstract: An anti-submarining seat cushion for a vehicle includes a main body constructed of an anisotropic material. The anisotropic material includes a primary material including a primary stiffness and a plurality of inserts that are dispersed throughout the primary material. The plurality of inserts exert an axial compressive force in response to the main body of the anti-submarining seat cushion experiencing a submarining load, where the axial compressive force is exerted in a direction that opposes the submarining load to increase an overall stiffness of the main body in a direction that aligns with the submarining load.

Abstract: A ceramic foam filter system includes a filter body having multiple tortuous path channels through the filter body to filter a molten liquid. A filter holder configuration defining a canister in a runner passage receives the filter body. An upstream end of the filter body receives the molten liquid having multiple inclusions. A predominant portion of the inclusions are larger than the multiple tortuous path channels and are trapped against the upstream end of the filter body. The multiple tortuous path channels are sized to trap a predominant portion of multiple oxides within the molten liquid as trapped oxides within the filter body. A filtered molten material having the multiple inclusions and the multiple oxides removed is directed from the multiple tortuous path channels as a discharge flow to exit at a downstream end of the filter body.

Abstract: A method to manufacture a ceramic foam filter includes: sintering a filter body to a temperature greater than a molten metal to be filtered through the body; creating multiple tortuous path channels extending through the filter body individually having a repeated and controlled passage geometry creating a continuously changing diameter and area of a flow path through the multiple tortuous path channels causing localized increases and decreases in molten metal flow rate through the multiple tortuous path channels; and applying a mixture of at least one ceramic powder and at least one binder using additive manufacturing to shape the filter body including the multiple tortuous path channels.

Abstract: An additive manufacturing method includes providing a first composite material and forming a composite part matrix using the first composite material and defining a first layer, applying a first fiber reinforcing material to the composite part matrix atop and in contact with the first layer of the composite part matrix such that fibers of the first fiber reinforcing material are oriented in a first direction and form a second layer on the composite part matrix, applying a second fiber reinforcing material to the composite part matrix atop and in contact with the first fiber reinforcing material such that fibers of the second fiber reinforcing material are oriented in a second direction orthogonal to the first direction and form a third layer on the composite part matrix, applying the first composite material to the composite part matrix, and curing the composite part matrix to create a composite product.

Abstract: An additive manufacturing method comprises: positioning a sheet of composite material; curing a predetermined portion of the sheet; cutting the sheet about the perimeter of the predetermined portion to create a preceding processed sheet; adding a successive sheet of composite material atop and in contact with the preceding processed sheet; curing a predetermined portion of the successive sheet such that the predetermined portions of the successive sheet and the preceding processed sheet are bonded together; and cutting the successive sheet about the perimeter of its predetermined portion to create a subsequent processed sheet. The steps of adding, curing and cutting a successive sheet may be repeated for a plurality of cycles to produce a three-dimensional composite product.

Abstract: A method of fabricating a mold for producing a part includes applying a network of sacrificial components onto a first surface of a mold base, wherein the sacrificial components are made of a sacrificial material, covering the network of sacrificial components and the first surface with a layer of a covering material, and removing the sacrificial material to produce a network of channels within the layer of covering material. The network of sacrificial components may be formed by additive manufacturing or by mechanical placement of a preformed network of sacrificial components.

Abstract: A structural instrument panel member for an instrument panel assembly of a vehicle comprises a cross beam, a steering column support, a first and second HVAC duct, and a first dash panel mount. The cross beam mount has a first surface, a first side, a second side and a first, second, third, fourth and fifth walls. The cross beam mount is fastened to a cross beam of the vehicle. The steering column support extends from the first side of the cross beam mount. The first and second HVAC duct each have a first end and a second end. The first HVAC duct is disposed on the second side of the cross beam mount and the second HVAC duct is disposed adjacent the first HVAC duct. The first dash panel mount extends from the first HVAC duct and fastened to a dash panel of the vehicle.

Abstract: A thermal management device for dissipating heat from an electrical component includes a volume of working fluid configured to change from a liquid state to a vapor state in response to being heated by the electrical component. The thermal management device also includes a working fluid chamber configured to move the working fluid. The working fluid chamber includes an impermeable outer portion and a porous inner portion integrally formed with and connected to the impermeable outer portion. The inner portion is configured to move the working fluid when in the liquid state toward the electrical component. The impermeable outer portion is made of a first material and the porous inner portion is made of a second material. The first material is different from the second material.

Abstract: A method of fabricating a mold includes 3D printing a first shell using a first material, the first shell having a first interior surface and a first exterior surface, and 3D printing a second shell using a second material different from the first material, the second shell having a second interior surface and a second exterior surface wherein the second interior surface generally conforms to the first exterior surface. The first material may be thermally conductive and the second material may be thermally insulative, and the first and/or second shell may include at least one thermal regulation element formed therein.

Abstract: An additive manufacturing method includes providing a first composite material and forming a composite part matrix using the first composite material and defining a first layer, applying a first fiber reinforcing material to the composite part matrix atop and in contact with the first layer of the composite part matrix such that fibers of the first fiber reinforcing material are oriented in a first direction and form a second layer on the composite part matrix, applying a second fiber reinforcing material to the composite part matrix atop and in contact with the first fiber reinforcing material such that fibers of the second fiber reinforcing material are oriented in a second direction orthogonal to the first direction and form a third layer on the composite part matrix, applying the first composite material to the composite part matrix, and curing the composite part matrix to create a composite product.

Abstract: An additive manufacturing method comprises: positioning a sheet of composite material; curing a predetermined portion of the sheet; cutting the sheet about the perimeter of the predetermined portion to create a preceding processed sheet; adding a successive sheet of composite material atop and in contact with the preceding processed sheet; curing a predetermined portion of the successive sheet such that the predetermined portions of the successive sheet and the preceding processed sheet are bonded together; and cutting the successive sheet about the perimeter of its predetermined portion to create a subsequent processed sheet. The steps of adding, curing and cutting a successive sheet may be repeated for a plurality of cycles to produce a three-dimensional composite product.

Abstract: A structural instrument panel member for an instrument panel assembly of a vehicle comprises a cross beam, a steering column support, a first and second HVAC duct, and a first dash panel mount. The cross beam mount has a first surface, a first side, a second side and a first, second, third, fourth and fifth walls. The cross beam mount is fastened to a cross beam of the vehicle. The steering column support extends from the first side of the cross beam mount. The first and second HVAC duct each have a first end and a second end. The first HVAC duct is disposed on the second side of the cross beam mount and the second HVAC duct is disposed adjacent the first HVAC duct. The first dash panel mount extends from the first HVAC duct and fastened to a dash panel of the vehicle.

Abstract: A vehicle seat cushion for a vehicle that includes a seat cushion support structure, and a lattice-structured support that is supported by the seat cushion support structure. The lattice-structured support provides a first resistive force in response to a vertically applied force that is less than a second resistive force in response to a force aligned with an H-point travel path of the vehicle occupant during a vehicle impact event.

Abstract: An airbag assembly for mounting above an occupant in a vehicle includes an airbag housing and an airbag cushion. The airbag cushion is connected to the housing and is deployable from an uninflated state to an inflated state. The airbag cushion includes a forward portion and a rearward portion. The forward portion is positioned closer to the occupant than the rearward portion when the airbag cushion is in the inflated state. The forward portion is also separated from the rearward portion by a void. The void configured to cause a head of the occupant to rotate forward relative to a torso of the occupant when the occupant contacts the airbag cushion.

Abstract: A seat cushion is provided. The seat cushion includes a first cushion comprising a top side and a bottom side. The bottom side or the top side includes a contoured area and the contoured area has a convex or a concave shape.

Abstract: A seat cushion is provided. The seat cushion includes a first cushion comprising a top side and a bottom side. The bottom side or the top side includes a contoured area and the contoured area has a convex or a concave shape.

Abstract: A system includes a climate control module and a thermal device control module. The climate control module, based on at least one of a user input and a first input from a temperature sensor that measures a temperature of a seat of a vehicle, generates one of (i) a heating command signal indicating an instruction to heat the seat and (ii) a cooling command signal indicating an instruction to cool the seat. The thermal device control module, in response to one of the heating command signal and the cooling command signal, controls at least one of a blower and at least one TED to one of heat and cool the seat based on a second input from at least one sensor that measures at least one of a pressure applied to the seat, a force applied to the seat, and a strain within the seat.