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 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: 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: 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: Some embodiments of the present disclosure relate to additively manufactured vehicle exterior structures, designed to enclose the vehicle surface and support required operational loads. The vehicle structure includes cavities into which components that require an external interface are inserted. A plurality of components are assembled and integrated into the vehicle structure. The structure may be 3-D printed using multiple printing techniques applied in parallel or in series. In an embodiment, the components and structure are modular, use multiple materials and manufacturing techniques, and enable reparability and replacement of single parts.

Abstract: A system and method is provided for manufacturing a composite structure. In an exemplary aspect, the system includes multiple flexible tooling plates that are interlocked to each other to form a tooling surface for forming a composite structure to be manufactured. Moreover, the system includes an actuator array connected to the flexible plates and that can move the flexible plates relative to each other to adjust a contour of the tooling surface to correspond to a design contour of the composite structure to be manufactured.

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: 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: A platform for building a plurality of vehicle types is disclosed. In an embodiment, a facility may include a processing system for designing a plurality of definition nodes for a vehicle and identifying a relative position for each definition node. Based on the design, the internal volume and other vehicle parameters can be determined. The facility includes a 3-D printer for additively manufacturing the definition nodes. In an embodiment, a plurality of commercial-off-the-shelf (COTS) parts are acquired and the definition nodes are designed to interface with the COTS parts. The facility may also include a station, or primary location where the major portions of the vehicle are assembled. In another embodiment, multiple such geographically-distributed facilities can be used, such that one facility can manufacture a desired vehicle type on behalf of another facility, e.g., in the event of an overflow.

Abstract: Techniques for using additively manufactured structures for doors are disclosed. These structures may include complex features and interfaces to enable connections to various systems in a door. The AM structure can include fasteners, hinges, hinge attachments and other structures which can advantageously be printed with the AM door structures.

Abstract: A system and method is provided for manufacturing a composite structure. In an exemplary aspect, the system includes multiple flexible tooling plates that are interlocked to each other to form a tooling surface for forming a composite structure to be manufactured. Moreover, the system includes an actuator array connected to the flexible plates and that can move the flexible plates relative to each other to adjust a contour of the tooling surface to correspond to a design contour of the composite structure to be manufactured.

Abstract: Systems and methods of co-printing a unitary hinge are provided. The unitary hinge may be co-printed using an additive manufacturing process. The unitary hinge includes a hinge pin that is substantially cylindrical in shape. The unitary hinge also includes a knuckle which surrounds a portion of the hinge pin and is configured to be manipulated about the hinge pin. The hinge pin is fabricated in situ with the knuckle such that further assembly is unnecessary. The unitary hinge may also include retention mechanism to retain the hinge within the knuckle without substantially restricting the knuckle from being rotated about the hinge pin. The unitary hinge may further be configured with a fluid port which may, for example, be used to provide a lubricant to an area between the hinge pin and the knuckle or to vacuum powder material or debris from the area.

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 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 providing universal interfaces between parts of a transport structure are disclosed. In one aspect of the disclosure, an apparatus for joining first and second parts of a transport structure includes an additively manufactured body having first and second surfaces. The first surface may connect to a first part such as, for example, a panel. The second surface may include a fitting for mating with a complementary fitting on a second part.

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: 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 additively manufactured vehicle exterior structures, designed to enclose the vehicle surface and support required operational loads. The vehicle structure includes cavities into which components that require an external interface are inserted. A plurality of components are assembled and integrated into the vehicle structure. The structure may be 3-D printed using multiple printing techniques applied in parallel or in series. In an embodiment, the components and structure are modular, use multiple materials and manufacturing techniques, and enable reparability and replacement of single parts.

Abstract: An automated wrapping technique for vehicle components is disclosed. A component to be wrapped is secured to a fixture, which in turn is coupled to an actuator. A grabber arm grabs a length of wrap from a feed roll. The grabber arm removes the backing and spreads the wrap over the component. The actuator pushes the component upward until the wrap contacts the component surface. An applicator may concurrently smooth the wrap and evacuate trapped air. The wrap may be cut around the periphery of the component, and hemmed. A controller provides instructions to automate the wrapping mechanism.