Abstract: A duct for a ducted-rotor aircraft includes a hub, a duct ring, and a plurality of stators that extend outward from the hub. The duct ring defines a trailing edge. The duct includes one or more fittings, such as a system of fittings. Each fitting has a body that defines a first attachment interface that is configured to couple to structure of the duct ring and a second attachment interface that is configured to couple to one of the plurality of stators. The first and second attachment interfaces are spaced from each other such that when the fittings are coupled to the duct ring and the plurality of stators, all or substantially all of each of the plurality of stators are located aft of the trailing edge of the duct ring.

Abstract: A ducted-rotor aircraft includes a fuselage, first and second ducts, and a spindle that is coupled to the fuselage. Each duct includes a rotor having a plurality of blades. The first and second ducts are coupled to opposed ends of the spindle. The spindle is rotatably coupled to the fuselage with first and second bearings. The first bearing is configured to react to radial loads and the second bearing is configured to react to both radial and axial loads. The spindle includes a shaft, first and second fittings secured to opposed ends of the shaft, and first and second attachment interfaces that are attachable to the first and second ducts. The attachment interfaces may be integral with the fittings. Alternatively, the fittings may be configured to be secured to the attachment interfaces with fasteners.

Abstract: A hub assembly for a ducted-rotor aircraft includes a plurality of stator supports, a first integral fitting that attaches to first ends of the stator supports, and a second integral fitting that attaches to second ends of the stator supports. The first fitting includes a plurality of motor attachment portions configured to locate and support a motor of the ducted-rotor aircraft, a plurality of fairing mounts configured to support attachment of an aerodynamic fairing to the hub assembly, and a plurality of stator locators configured to locate respective ones of the plurality of stator supports for attachment to the hub assembly. The first fitting has a body portion with an annular wall that supports the motor attachment portions, the fairing mounts, and the stator locators. The first fitting may be fabricated as a monolith that includes the body portion, motor attachment portions, fairing mounts, and stator locators.

Abstract: A duct for a ducted-rotor aircraft may include an internal structure and an aerodynamic exterior skin that is adhesively bonded to the internal structure. The skin may include a leading-edge portion disposed at an inlet of the duct and an inner portion disposed along an interior of the duct. The inner portion of the skin may be bonded to the internal structure with a first bondline of adhesive and the leading-edge portion of the skin may be bonded to the inner portion of the skin with a second bondline of adhesive. One or both of the first and second bondlines of adhesive may be of non-uniform thickness to take up tolerance stackups between the inner portion of the skin, the leading-edge portion of the skin, and the internal structure.

Abstract: A duct for a ducted-rotor aircraft may include internal structural components such as a spindle that is supported by a fuselage of the aircraft, first and second annular spars that are attached to an end of the spindle, a central hub that supports a motor of the aircraft, a plurality of stators that extend from the central hub to the second spar, and a plurality of ribs that are attached to the first spar and the second spar at respective opposed ends. The spindle may include an attachment interface to which the first and second spars are attached. The attachment interface may be disposed at the second end of the spindle. The attachment interface may define first and second arc-shaped planar surfaces to which the first and second spars, respectively, are attached.

Abstract: An annular spar for a ducted-rotor of an aircraft may be fabricated from composite material, such as carbon-fiber-reinforced plastic (CFRP). The spar may include an annular plate, a first circumferential flange that extends from an outer edge of the plate, and a second circumferential flange that extends from an inner edge of the plate. The first and second circumferential flanges may taper inwardly toward a center axis of the spar. The spar may be constructed of a plurality of layers of CFRP. One or more of the layers may be fabricated from a single ply of CFRP, and one or more other layers may be fabricated from a plurality of plies of CFRP. The spar may exhibit a coefficient of thermal expansion (CTE) that allows an associated tip gap to remain essentially constant throughout a range of operating temperatures.

Abstract: An apparatus for injecting molten metal into a die cast machine is provided. The apparatus includes a molten metal reservoir having a first open end in fluid communication with a die casting mold and a second open end. The molten metal reservoir includes at least one first cooling fluid path positioned about at least a portion of an outer surface of the molten metal reservoir and in thermal contact with the molten metal reservoir. The apparatus further includes a plunger sized to fit within the second open end. The plunger includes a plunger tip and a second cooling fluid path defined within the plunger tip and in thermal contact with the molten metal reservoir. A plurality of thermal actuators are also provided. Each of the plurality of thermal actuators controls a volume of cooling fluid flowing through one first cooling fluid path of the at least one first cooling fluid path or the second cooling fluid path.

Abstract: This application discloses a standoff device for surface-mounting light emitting diodes (LEDs). In some embodiments, the standoff has asymmetric features to control orientation of a part in tube or reel packaging. The standoff has a broad base to keep the part upright during the reflow process. The standoff has a lifted bottom surface to allow room for solder flowing onto leads. The standoff has lead holes spaced at a standard distance to hold many different LEDs. In addition, the standoff has a variable height designed to allow one mold to make parts of different heights.

Abstract: A melt furnace including a first reservoir, a second reservoir, a holding reservoir, and a control system including a controller is provided. The first reservoir and the second reservoir are in fluid communication with the holding reservoir to flow molten materials to the holding reservoir. The controller is in communication with a first material level sensor, a second material level sensor, a holding reservoir temperature sensor, and a molten material level sensor assembly. The controller is adapted to adjust an output level of at least one of the first reservoir melt burner and the second reservoir melt burner based, at least in part, on one or more received signals to control the flow of molten materials from the first reservoir and the second reservoir to maintain a level of molten material in the holding reservoir.

Abstract: This application discloses a standoff device for surface-mounting light emitting diodes (LEDs). In some embodiments, the standoff has asymmetric features to control orientation of a part in tube or reel packaging. The standoff has a broad base to keep the part upright during the reflow process. The standoff has a lifted bottom surface to allow room for solder flowing onto leads. The standoff has lead holes spaced at a standard distance to hold many different LEDs. In addition, the standoff has a variable height designed to allow one mold to make parts of different heights.

Abstract: An aircraft cabin pressure control system outflow thrust recovery valve includes a frame, a valve element, and actuation hardware. The frame, valve element, and at least a portion of the actuation hardware are made of composite material. The actuation hardware is disposed external to the frame.

Abstract: An apparatus for injecting molten metal into a die cast machine is provided. The apparatus includes a molten metal reservoir having a first open end in fluid communication with a die casting mold and a second open end. The molten metal reservoir includes at least one first cooling fluid path positioned about at least a portion of an outer surface of the molten metal reservoir and in thermal contact with the molten metal reservoir. The apparatus further includes a plunger sized to fit within the second open end. The plunger includes a plunger tip and a second cooling fluid path defined within the plunger tip and in thermal contact with the molten metal reservoir. A plurality of thermal actuators are also provided. Each of the plurality of thermal actuators controls a volume of cooling fluid flowing through one first cooling fluid path of the at least one first cooling fluid path or the second cooling fluid path.

Abstract: A melt furnace including a first reservoir, a second reservoir, a holding reservoir, and a control system including a controller is provided. The first reservoir and the second reservoir are in fluid communication with the holding reservoir to flow molten materials to the holding reservoir. The controller is in communication with a first material level sensor, a second material level sensor, a holding reservoir temperature sensor, and a molten material level sensor assembly. The controller is adapted to adjust an output level of at least one of the first reservoir melt burner and the second reservoir melt burner based, at least in part, on one or more received signals to control the flow of molten materials from the first reservoir and the second reservoir to maintain a level of molten material in the holding reservoir.

Abstract: A system includes a first sensor positioned at a first location that senses a pallet identifier associated with a transfer pallet. A component is associated with the transfer pallet. A second sensor positioned at a second location remote from the first sensor senses the pallet identifier associated with the transfer pallet. A marking machine proximate to the second location marks the component with a component identifier associated with component unique birth data based on the pallet identifier.

Abstract: A method for testing casting quality includes collecting sand that has fallen from an internal cavity of the casting at a collection area. The collection area includes a screen and a pad. The method further includes capturing a first image of sand that has fallen onto the pad and analyzing the first image to determine an amount of black sand that has fallen onto the pad. The method further includes capturing a second image of sand that has been retained on the screen and analyzing the second image to determine an amount of black sand chunks retained on the screen.

Abstract: An aircraft cabin pressure control system outflow thrust recovery valve includes a frame, a valve element, and actuation hardware. The frame, valve element, and at least a portion of the actuation hardware are made of composite material. The actuation hardware is disposed external to the frame.

Abstract: An aircraft cabin pressure control system outflow thrust recovery valve includes a frame, a valve element, and actuation hardware. The frame, valve element, and at least a portion of the actuation hardware are made of composite material. The actuation hardware is disposed external to the frame.

Abstract: A method for testing casting quality includes collecting sand that has fallen from an internal cavity of the casting at a collection area. The collection area includes a screen and a pad. The method further includes capturing a first image of sand that has fallen onto the pad and analyzing the first image to determine an amount of black sand that has fallen onto the pad. The method further includes capturing a second image of sand that has been retained on the screen and analyzing the second image to determine an amount of black sand chunks retained on the screen.

Abstract: A system includes a first sensor positioned at a first location that senses a pallet identifier associated with a transfer pallet. A component is associated with the transfer pallet. A second sensor positioned at a second location remote from the first sensor senses the pallet identifier associated with the transfer pallet. A marking machine proximate to the second location marks the component with a component identifier associated with component unique birth data based on the pallet identifier.

Abstract: An aircraft cabin pressure control system outflow thrust recovery valve includes a frame, a valve element, and actuation hardware. The frame, valve element, and at least a portion of the actuation hardware are made of composite material. The actuation hardware is disposed external to the frame.