Abstract: A defect detection system includes: sensors of different types configured to scan battery electrode material and generate output signals including respective image data; a feature extractor module receives the output signals and performs feature extraction to fuse the image data of the output signals to generate feature maps for respective portions of the battery electrode material; a coarse detector, based on the feature maps, determines whether there are defects in the portions of the battery electrode material, and generates binary information for each of the portions indicating whether the portions include one or more defects; and a fine detector, based on the binary information and at least one of the feature maps and image data, classifies the defects. A control module performs one or more operations based on the detected and classified defects.

Abstract: A system includes a station to support a workpiece having one or more welds and/or surface features, and first and second vision sensing assemblies. The first assembly is configured to illuminate the workpiece and generate an image of the one or more welds and/or surface features. The first assembly includes a first light source configured to emit light having a first wavelength and a first sensor configured to detect the light having the first wavelength reflected by the workpiece. The second assembly is configured to illuminate the workpiece and generate an image of the one or more welds and/or surface features. The second assembly includes a second light source configured to emit light having a second wavelength and a second sensor configured to detect the light having the second wavelength reflected by the workpiece. Other example systems and methods are also disclosed.

Abstract: A method for providing a vehicle with a multi-tone paint scheme, the method including: applying a first paint of a first color to a body of the vehicle with a panel of the vehicle detached from the body of the vehicle; applying a film onto the panel, the film including a second paint of a second color that is different from the first color; and mounting the panel to the body of the vehicle.

Abstract: A method for painting a body of a vehicle with a multi-tone paint scheme. The method includes: applying a first paint of a first color to the body; oven-curing the first paint; applying a second paint of a second color to the body, the second paint configured to be cured by ultraviolet light, the second color is different from the first color, and curing the second paint by exposing the second paint to ultraviolet light.

Abstract: A painting system includes a mobile robot including a frame, wheels connected to the frame, and a motor configured to move the wheels to position the mobile robot. A paint container is mounted on the mobile robot and configured to store paint. A robot arm includes a first end mounted on the mobile robot and a paint applicator arranged at a second end of the robot arm. The paint applicator is in fluid communication with the paint container and includes one or more nozzles to spray the paint onto a surface.

Abstract: An overspray-free paint system includes: a paint robot including an overspray-free paint applicator; and a first fixture robot for lifting and orienting a fixture assembly relative to at least one of the paint robot and the overspray-free paint applicator, the fixture assembly configured to hold an object to be painted by the overspray-free paint applicator, the first fixture robot including a first gripper configured to grab a first portion of the fixture assembly, and the first fixture robot configured to lift and orient the fixture assembly via the first gripper.

Abstract: An overspray-free paint system includes: a paint robot including an overspray-free paint applicator; and a first fixture robot for lifting and orienting a fixture assembly relative to at least one of the paint robot and the overspray-free paint applicator, the fixture assembly configured to hold an object to be painted by the overspray-free paint applicator, the first fixture robot including a first gripper configured to grab a first portion of the fixture assembly, and the first fixture robot configured to lift and orient the fixture assembly via the first gripper.

Abstract: A method of forming additive energy directors according to various exemplary embodiments can include dispensing a molten material onto a substrate at a predetermined location. The method also includes solidifying the molten material to form at least one additive energy director onto the substrate.

Abstract: A ultrasonic welding method of joining dissimilar-material workpieces, such as sheet materials, and the joined components formed thereby. The method includes applying ultrasonic energy to a thermoplastic piece to fill a hole of a dissimilar piece to form a weld point that is made up with polymer from the thermoplastic piece. In general, the geometry of the thermoplastic piece is not altered during the process. The dissimilar piece generally has a higher melting temperate and can be metal, thermoset polymers, or other thermoplastic material. The welded pieces can be arranged in a lap, laminate, or double lap configuration. In some embodiments, the hole of the dissimilar sheet material includes undercut features that improve the mechanical interlock between the dissimilar pieces. In some embodiments, the weld point has a mushroom cap to improve mechanical interlock.

Abstract: During an example coating method, a metallic substrate is provided. A foundation coat precursor is applied on the metallic substrate. The foundation coat precursor includes a matrix and a plurality of capsules present in the matrix. Each capsule includes a shell and a healing agent surrounded by the shell. A basecoat precursor is applied, and a clearcoat precursor is applied. The metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor are heated i) after each respective application or ii) simultaneously, in order to cure the foundation coat, basecoat, and clearcoat precursors and respectively form a foundation coat, a basecoat, and a clearcoat. The foundation coat is ultraviolet (UV) stable and bonds the metallic substrate to the basecoat and the clearcoat.

Abstract: A method for joining a plurality of workpieces includes providing a rotating drive tool. A fastener is secured to the drive tool. The drive tool is then rotatably driven such that a distal end of the fastener rotates against a surface of the plurality of workpieces. A heated material zone is then generated on the plurality of workpieces as caused by friction from the rotation of the fastener against the surface of the plurality of workpieces. The distal end of the fastener is rotatably and axially driven through the heated material zone. Finally, the drive tool is removed from the fastener, such that when the heated material zone cools, a portion of the heated material zone is fused to the fastener.

Abstract: A method of forming a layer on a first component according to various aspects of the present disclosure includes melting a portion of a first metallic composition of the first component. The melting includes directing a laser beam toward a first surface of the first component. The method further includes depositing a second metallic composition on the first surface by directing a precursor including the second metallic composition toward an intersection of the first surface and the laser beam. The second metallic composition is galvanically more noble than the first metallic composition. The method further includes forming the layer on the first component by solidifying the first metallic composition and the second metallic composition. The first component is configured to be joined to a second component by engaging a plurality of micro-anchors defined on the layer with a polymer of the second component.

Abstract: Methods and devices for manufacturing paneled structures are provided. The methods include manufacturing a frame structure by additive manufacturing methods and scanning a surface of the frame structure to determine whether there is more than a nominal surface deviation at a location where a panel will be disposed. When there is more than a nominal surface deviation, the methods also include generating a panel to be disposed at the location of the frame structure, wherein the panel has an engagement surface that is complimentary to the surface deviation.

Abstract: The present disclosure provides a metal-polymeric composite joint including a first component and a second component. The first component includes a metal. The first component has a first surface including a plurality of micro-anchors. The second component includes a composite material including a polymer and a reinforcing fiber. The second component has a second surface that at least partially engages the first surface of the first component. A portion of the polymer of the second component occupies at least a portion of the micro-anchors of the first component to fix the second component to the first component. In one aspect, the metal-polymeric composite joint further includes a passivation layer disposed between the first surface of the first component and the second surface of the second component.

Abstract: Methods and systems are provided for generating a mold. In one embodiment, a method includes: determining, by a processor, a fiber orientation for a plurality of points in a part; determining, by the processor, a distortion value based on the fiber orientations; and generating, by the processor, mold dimensions based on the distortion values.

Abstract: During an example coating method, a metallic substrate is provided. A foundation coat precursor is applied on the metallic substrate. The foundation coat precursor includes a matrix and a plurality of capsules present in the matrix. Each capsule includes a shell and a healing agent surrounded by the shell. A basecoat precursor is applied, and a clearcoat precursor is applied. The metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor are heated i) after each respective application or ii) simultaneously, in order to cure the foundation coat, basecoat, and clearcoat precursors and respectively form a foundation coat, a basecoat, and a clearcoat. The foundation coat is ultraviolet (UV) stable and bonds the metallic substrate to the basecoat and the clearcoat.

Abstract: A method for laser welding of non-transmissive composite materials includes: forming an energy channel having an end opening and extending through a first part made of a first material; and welding a second part made of a second material to the first part via laser heating of the materials of the first and second parts proximate to the end opening of the energy channel such that the materials of the first and second parts fuse to form a weld nugget, attaching the first part to the second part.

Abstract: A resistance spot welding method can be used to join polymeric and metallic workpieces together and includes the following steps: (a) placing an electrically conductive coating between a polymeric workpiece and a metallic workpiece, wherein the metallic workpiece has a textured surface facing the polymeric workpiece; (b) piercing the polymeric workpiece with first and second electrically conductive pins of a welding electrode assembly; (c) applying electrical energy to the first and second electrically conductive pins so that an electrical current flows through the first electrically conductive pin, the electrically conductive coating, and the second electrically conductive pin in order to at least partially melt the polymeric workpiece and the electrically conductive coating, thereby forming a weld pool; and (d) cooling the weld pool to form a solid weld nugget in order to establish a mechanical interface lock between the solid weld nugget and the textured surface.

Abstract: During an example coating method, a metallic substrate is provided. A foundation coat precursor is applied on the metallic substrate. The foundation coat precursor includes a matrix and a plurality of capsules present in the matrix. Each capsule includes a shell and a healing agent surrounded by the shell. A basecoat precursor is applied, and a clearcoat precursor is applied. The metallic substrate, the foundation coat precursor, the basecoat precursor, and the clearcoat precursor are heated i) after each respective application or ii) simultaneously, in order to cure the foundation coat, basecoat, and clearcoat precursors and respectively form a foundation coat, a basecoat, and a clearcoat. The foundation coat is ultraviolet (UV) stable and bonds the metallic substrate to the basecoat and the clearcoat.

Abstract: A ultrasonic welding method of joining dissimilar-material workpieces, such as sheet materials, and the joined components formed thereby. The method includes applying ultrasonic energy to a thermoplastic piece to fill a hole of a dissimilar piece to form a weld point that is made up with polymer from the thermoplastic piece. In general, the geometry of the thermoplastic piece is not altered during the process. The dissimilar piece generally has a higher melting temperate and can be metal, thermoset polymers, or other thermoplastic material. The welded pieces can be arranged in a lap, laminate, or double lap configuration. In some embodiments, the hole of the dissimilar sheet material includes undercut features that improve the mechanical interlock between the dissimilar pieces. In some embodiments, the weld point has a mushroom cap to improve mechanical interlock.