Abstract: A foam sheet core, including a plurality of foam sheet walls defining an array of hollow cells, wherein the plurality of foam sheet walls are bonded together to form the array of hollow cells, each of the plurality of foam sheet walls has a thickness from about 0.002 inches to about 0.08 inches, and each of the plurality of foam sheet walls has an average height from about 0.05 inches to about 5 inches.

Abstract: An aerial vehicle includes a wing body, a first wingtip, a second wingtip, a first edge, and a second edge. The aerial vehicle includes a pair of coaxial rotors configured to rotate in opposite rotational directions about a vehicle axis and a drive assembly configured to rotate the coaxial rotors. A controller is configured to selectively control thrust produced by the coaxial rotors. Selective control of the thrust produced by the coaxial rotors induces a pitch motion of the aerial vehicle to transition between a horizontal flight state and a vertical flight state. In the horizontal flight state, a collective thrust from the coaxial rotors is directed forward. In the vertical flight state, the collective thrust from the coaxial rotors is directed upward.

Abstract: Various techniques are provided to utilize nanostructures for process monitoring and feedback control. In one example, a method includes forming a layer of material including nanostructures distributed therein. Each nanostructure includes a quantum dot and a shell encompassing the quantum dot. The shells and quantum dots are configured to emit a first and second wavelength, respectively, in response to an excitation signal. The method further includes applying the excitation signal to at least a portion of the layer of material. The method further includes detecting an emitted signal from the portion of the layer of material, where the emitted signal is provided by at least a subset of the nanostructures in response to the excitation signal. The method further includes determining whether a manufacturing characteristic has been satisfied based at least on a wavelength of the emitted signal. Related systems and products are also provided.

Abstract: Methods and apparatus for UAV-enabled marking of surfaces during manufacture, inspection, or repair of limited-access structures and objects. A UAV is equipped with a marking module that is configured to apply marking patterns (e.g., alignment features) of known dimensions to surfaces. The marking module may include a 2-D plotter that enables free-form drawing capability. The marking process may involve depositing material on the surface. The marking material may be either permanent or removable. A “clean-up” module may be attached to the UAV platform instead of the marking module, and may include solvents and oscillating or vibrating pads to remove the marks via scrubbing. The clean-up module can also be used for initial surface preparation.

Abstract: Systems and methods for tracking the location of a non-destructive inspection (NDI) scanner using scan data converted into images of a target object. Scan images are formed by aggregating successive scan strips acquired using one or two one-dimensional sensor arrays. An image processor computes a change in location of the NDI scanner relative to a previous location based on the respective positions of common features in partially overlapping scan images. The performance of the NDI scanner tracking system is enhanced by: (1) using depth and intensity filtering of the scan image data to differentiate features for improved landmark identification during real-time motion control; and (2) applying a loop-closure technique using scan image data to correct for drift in computed location. The enhancements are used to improve localization, which enables better motion control and coordinate accuracy for NDI scan data.

Abstract: Wearable ergonomics improvement systems and related methods are disclosed. An example ergonomics improvement system includes a membrane including a first frame having a plurality of first cutouts defining a first pattern. The system includes a sensor coupled to the membrane and includes a second frame having a plurality of second cutouts defining a second pattern. The first pattern is complementary to the second pattern.

Abstract: Rotation hoists are disclosed. A disclosed example rotation hoist to support a component includes a platform having a first end and a second end opposite the first end, a body supported by the platform, a rotator supported by the body, the rotator couplable to the component at a first position of the component, and an arm extending from the rotator, the arm couplable to the component at a second position of the component different from the first position, the rotator to rotate the arm to rotate the component.

Abstract: Certain aspects of the present disclosure provide techniques for a method, including: receiving multi-dimensional event data associated with a vehicle event; determining, based on the multi-dimensional event data, an inspection classification for the vehicle event; receiving multi-dimensional analysis data associated with the inspection classification for the vehicle event; determining, based on the multi-dimensional analysis data, a repair classification for the vehicle event; receiving multi-dimensional action data associated with the repair classification for the vehicle event; and determining, based on the multi-dimensional action data, a monitoring classification for the vehicle event.

Abstract: A nozzle for dispensing adhesive between a first part and a second part comprises a nozzle body. The nozzle body comprises a first-part engagement surface. The nozzle body also comprises a second-part engagement surface, contiguous with the first-part engagement surface and defining an engagement-surface angle, greater than 0° and less than 180°, with a virtual plane, coincident with the first-part engagement surface. The nozzle body further comprises a nozzle-body outlet port, formed in the second-part engagement surface. The nozzle body additionally comprises a nozzle-body inlet port, formed in the first-part engagement surface. The nozzle also comprises a separator plate, coupled with and extending from the nozzle body.

Abstract: A method includes obtaining, at an unmanned aerial vehicle, a flight plan for the unmanned aerial vehicle. The flight plan is based on an aircraft type of an aircraft to be inspected. The method also includes coordinating, with a control device onboard the aircraft, an operation of a particular device of the aircraft based on the flight plan such that a state of the particular device changes when a particular sensor of the one or more sensors is located (i.e., positioned and oriented) to perform a sensing operation on the particular exterior light. The method further includes performing the sensing operation on the particular device using the particular sensor. The method also includes determining a functionality metric associated with the particular device based on the sensing operation.

Abstract: A system and method for detecting an anomaly of an optically transparent or translucent object are disclosed. The system and method include a light source configured to emit light, a light transmission element having a textured surface, and an optical couplant configured to be disposed between the light transmission element and the object. At least a portion of the light emitted by the light source is configured to pass into the light transmission element through the textured surface and pass into the object through the optical couplant. At least a portion of the light that passes into the object internally reflects within the object and impinges on the anomaly to provide an illumination that indicates the location of the anomaly.

Abstract: Systems and methods for automated swapping of a charged replacement battery for a depleted battery onboard an electric vehicle using a battery delivery vehicle (BDV). The BDV may be configured to operate autonomously or under remote control. The electric vehicle which receives the replacement battery from a BDV may be configured to operate autonomously (e.g., an AGV) or non-autonomously (e.g., an electric passenger car). The BDV is loaded with a fully (or partially) charged battery, and then moved to a rendezvous place at which the BDV is underneath and aligned with the electric vehicle. The battery is uploaded to the electric vehicle while the aligned BDV moves in tandem with the electric vehicle. After the replacement battery has been installed, the power distribution system onboard the electric vehicle switches over to draw DC power from the replacement battery (instead of from a depleted battery) without interrupting vehicle operation.

Abstract: A material system including a plurality of expandable pellets or a monolithic flexible carrier is disclosed, each of which may include a polymer matrix configured to hold an expandable core, and a flexible skin configured to encapsulate the polymer matrix, and where the flexible skin is at least partially permeable with respect to the expandable core or a gas released by the expandable core. Implementations of the material system may include where the polymer matrix may include a thermoplastic polymer. The material system may include a charging source configured to introduce blowing agent. A method of curing a composite part is also described.

Abstract: In an example, a method of sealing a bond cavity is described. The method comprises placing an adhesive around a perimeter of a first structure to be joined to a second structure. The method also comprises positioning the first structure relative to the second structure such that the adhesive is disposed between the first structure and the second structure. The method also comprises merging the first structure and the second structure until the first structure and the second structure are separated by a desired gap for bonding. The method also comprises heating the perimeter to at least partially cure the adhesive to form a leak-proof bond cavity perimeter between the first structure and the second structure.

Abstract: An example method of joining a first structure and a second structure is described that includes forming a bond cavity between a first structure and a second structure, placing a semi-permeable breather material at one or more exits of the bond cavity, placing a vacuum bag around the bond cavity and the semi-permeable breather material, evacuating the bond cavity via a vacuum port and forcing adhesive into the bond cavity via an adhesive port while the bond cavity is evacuated, and curing the adhesive via one or more heaters to bond the first structure to the second structure.

Abstract: A method for wirelessly coupling respective transducers of an automated motion platform and a sub-surface sensor node through a skin of a limited-access structure for the purpose of wireless power and data transfer. Coordinates of an as-designed position of the transducer of the sensor node in a local coordinate system of the limited-access structure are retrieved from a non-transitory tangible computer-readable storage medium. Then coordinates of a target position on an external surface of the skin of the limited-access structure are estimated. The target position is calculated to be aligned with the as-designed position of the transducer of the sensor node. The motion platform is moved under computer control so that the transducer onboard the motion platform moves toward the target position. Movement ceases when the transducer onboard the motion platform is at the target position. Then wave energy is transferred between the aligned transducers.

Abstract: Systems and methods for automated swapping of a charged replacement battery for a depleted battery onboard an electric vehicle using a battery delivery vehicle (BDV). The BDV may be configured to operate autonomously or under remote control. The electric vehicle which receives the replacement battery from a BDV may be configured to operate autonomously (e.g., an AGV) or non-autonomously (e.g., an electric passenger car). The BDV is loaded with a fully (or partially) charged battery, and then moved to a rendezvous place at which the BDV is underneath and aligned with the electric vehicle. The battery is uploaded to the electric vehicle while the aligned BDV moves in tandem with the electric vehicle. After the replacement battery has been installed, the power distribution system onboard the electric vehicle switches over to draw DC power from the replacement battery (instead of from a depleted battery) without interrupting vehicle operation.

Abstract: A material system including a plurality of expandable pellets or a monolithic flexible carrier is disclosed, each of which may include a polymer matrix configured to hold an expandable core, and a flexible skin configured to encapsulate the polymer matrix, and where the flexible skin is at least partially permeable with respect to the expandable core or a gas released by the expandable core. Implementations of the material system may include where the polymer matrix may include a thermoplastic polymer. The material system may include a charging source configured to introduce blowing agent. A method of curing a composite part is also described.

Abstract: A method of curing a composite part, including placing an uncured composite part on a mandrel, placing a plurality of expandable pellets on the uncured composite part, expanding the plurality of expandable pellets, applying a positive pressure to the uncured composite part, and curing the uncured composite part.

Abstract: A self-powered sensor node includes a printed wiring board connected to a patch. The printed wiring board includes a microcontroller, a transceiver, an antenna, and a power management module connected to supply electric power to the microcontroller. The patch comprises a metamaterial substrate and a piezoelectric element adhered to the metamaterial substrate. The piezoelectric element is connected to the power management module and to the microcontroller. The power management module is configured to store electric power received from the piezoelectric element. The microcontroller is configured to selectively convert electrical signals received from the piezoelectric element into sensor data and then command the transceiver to transmit the sensor data via the antenna. The metamaterial substrate has an auxetic kirigami honeycomb structure.