Abstract: A dual-mode suspension system using hydraulic dampers is disclosed. One or more dampers on each side of the four-wheel suspension system are coupled to a respective damper on the other side via a damper valve. One or more leaf springs may be arranged between the leading links coupled to some of the dampers, and trailing links coupled to other of the dampers. The suspension system may advantageously engage, lock, or partially disengage the respective dampers connected by the valve on each side of the system. Manipulating the valve to control engagement of the dampers, which may depend on the speed and related issues, provides control over whether heave motions should be separated from roll. In another embodiment, one or more single or double acting hydraulic cylinders may be used to engage dampers.

Abstract: Wheel assembles using integrated motors and speed reducers for electric vehicles are disclosed for providing improved structural efficiency. A wheel assembly may include a motor for providing power to a wheel, a leading or trailing type or similar suspension link, a caliper mounted to the suspension link and configured to engage a friction brake rotor on the wheel, and a synchronous belt mounted off-axis for implementing speed reducing. In certain embodiments, the respective components of the wheel assembly are nested to fit into a minimal volume. In other embodiments, the wheel assembly includes a motor that is not nested and that is configured to supply power to the wheel via a belt and pulley system.

Abstract: A solar extended range electric vehicle, various structures and assemblies within the vehicle, and additive manufacturing techniques for these structure and assemblies are disclosed. In an aspect of the present disclosure, a solar extended-range vehicle includes a frame coupled to an exterior structure, a suspension system mounted to the exterior structure and coupled to a wheel system, at least one electric motor coupled to the wheel system, and at least one stowable solar panel arranged along a region of the frame for supplying power to the electric motor.

Abstract: A solar extended range electric vehicle includes panel deployment and emitter tracking features. In one aspect, the vehicle includes one or more deployment motors for deploying the solar panels from their closed position upon activation of a stationary mode. In another aspect, the vehicle provides dynamic emitter tracking in the stationary mode. For example, the one or more deployment motors and/or counterpart processing systems are configured in one embodiment, to rotate, translate, or otherwise orient their respective solar panels to track the sun. The vehicle may further include a dynamic leaning suspension system as an additional or alternative emitter tracking mechanism.

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 nodes, extrusions, and panels are presented herein. Nodes, extrusions, and panels can be joined together using adhesive joining techniques. The adhesive joining techniques can be applied to additively manufactured nodes or extrusions, and sandwich panels. Sandwich panels can be additively manufactured and/or commercial off the shelf (COTS) components. There can be more than one type of a joint formed by the joining techniques. Exemplary types of j oints can use a liquid adhesive in conjunction with a vacuum and/or a film foam adhesive.

Abstract: One aspect is an apparatus including a node having a socket configured to receive a component and a detachable additively manufactured nozzle co-printed with the node and arranged for adhesive injection between the component and the socket. Another aspect is an additively manufactured apparatus including a first additively manufactured component having an area configured to receive a second additively manufactured component. The first component includes an adhesive channel for injecting adhesive into the area when the second component is being connected to the first component. Another 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.

Abstract: Techniques for integrating a machine-readable matrix with a component of a mechanical structure using three-dimensional (3-D) printing are disclosed. Such techniques include generating at least one data model representing the component, and projecting a matrix pattern identifying one or more features of the component onto a selected surface portion of the component to produce a modified data model for use as an input to a 3-D printer.

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: Systems and methods of support structures in powder-bed fusion (PBF) are provided. Support structures can be formed of bound powder, which can be, for example, compacted powder, compacted and sintered powder, powder with a binding agent applied, etc. Support structures can be formed of non-powder support material, such as a foam. Support structures can be formed to include inductive components that can be used to facilitate removal of the support structures in the presence of an external magnetic field. Additionally, support structures can be formed to break when a fluid, such as air or water, creates a force and/or pressure at a connection point interface.

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: 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: One aspect is an apparatus including an additively manufactured first component and a captive nut contained within the first component for interconnecting the first component to a second component. Another aspect is an apparatus including a first additively manufactured component having a hole and a second additively manufactured component having a socket. The apparatus further includes a pin having a head engaging a surface of the first component and a shaft extending from the head through the hole in the first component and into the socket of the second component. Another aspect is an apparatus including first and second panels. The apparatus also includes a bolt having a head and a shaft extending from the head and a nut located at a distal end of the shaft. The first and seconds panels may be sandwiched between the bolt and nut to interconnect the first and second panels.

Abstract: Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node. The apparatus includes an additively manufactured interconnect co-printed with the node. The interconnect is configured to connect the node to a component.

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: Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node having a socket. The apparatus includes one or more locating features co-printed with the node. The one or more locating features are configured to locate an end portion of a component in the socket.

Abstract: Systems and methods for material handling in additive manufacturing systems are provided. Environmental control can decrease exposure of a powder to substances that change a material property of the powder and/or that change a property of a build piece formed from fusing the powder. Powders can be mixed for use in PBF systems. For example, a powder that has been through a printing operation can be reused by mixing the reuse powder with new powder. Powder can be recovered after a printing operation and reused, recycled into new powder, etc. Powder can be decontaminated for better reusability.

Abstract: Techniques for flexible, on-site additive manufacturing of components or portions thereof for transport structures are disclosed. An automated assembly system for a transport structure may include a plurality of automated constructors to assemble the transport structure. In one aspect, the assembly system may span the full vertically integrated production process, from powder production to recycling. At least some of the automated constructors are able to move in an automated fashion between the station under the guidance of a control system. A first of the automated constructors may include a 3-D printer to print at least a portion of a component and to transfer the component to a second one of the automated constructors for installation during the assembly of the transport structure. The automated constructors may also be adapted to perform a variety of different tasks utilizing sensors for enabling machine-learning.

Abstract: Apparatus and methods for joining panels are presented. Panels may be commercial off the shelf (COTS) panels and/or additively manufactured panels; and panels can be joined using an additively manufactured interconnect unit. Notches and protrusions can be formed in the panels and in the interconnect unit to facilitate the connection of the panels with the interconnect unit. In another approach a ribbed triangular prism can be manufactured using three dimensional (3D) printing. The panels can then be joined by inserting the ribbed triangular prism between the panels and by using an adhesive for bonding.

Abstract: Systems and methods for beam scanning for powder bed fusion (PBF) systems are provided. A PBF apparatus can include a structure that supports a layer of powder material, an energy beam source that generates an energy beam, and a deflector that applies the energy beam to fuse an area of the powder material in the layer at multiple locations, the deflector being further configured to apply the energy beam to each of the locations multiple times. A PBF apparatus can include a deflector configured to provide multiple scans to a layer powder material supported by the structure. A PBF apparatus can include a deflector that applies the energy beam to fuse an area of the powder material in the layer at multiple locations, the deflector being further configured to apply the energy beam in a raster scan.