Abstract: A tool for forming a composite part and a method of making the tool and the composite part are disclosed. The tool includes a top surface that supports the composite part during forming, the top surface comprising a first lateral portion and a second lateral portion arranged on either side of a central part contacting surface; a first integrated heat sink arranged on an opposite surface of the top surface, wherein a shape of the first integrated heat sink is based on a thermal topology optimization process of the tool; a first vacuum port arranged at a first location on the first lateral portion; and a second vacuum port arranged at a second location on the first lateral portion, wherein the first vacuum port and the second vacuum port provide access to a vacuum pump to provide at least a partial vacuum to the top surface during composite part formation.

Abstract: Disclosed herein is an additively manufactured multi-layered ballistic armor and a method of forming a multi-layered ballistic armor. The multi-layered ballistic armor includes a metal layer and a ceramic layer. The metal layer includes first mechanical interconnection features and a plurality of first pores. The ceramic layer includes second mechanical interconnection features configured to mechanically interconnect with the first mechanical interconnection features and a plurality of second pores.

Abstract: A bladder. The bladder includes a bladder wall include first dimensions. The bladder also includes a first port disposed in the bladder wall. The bladder also includes knitted seams stitched into a first pattern in the bladder wall. The first pattern is configured such that when the bladder wall is subjected to a compressive force, the bladder collapses into a first pre-determined shape that has second dimensions less than the first dimensions.

Abstract: A tool for forming a composite part and a method of making the tool and the composite part are disclosed. The tool includes a top surface that supports the composite part during forming, the top surface comprising a first lateral portion and a second lateral portion arranged on either side of a central part contacting surface; a first integrated heat sink arranged on an opposite surface of the top surface, wherein a shape of the first integrated heat sink is based on a thermal topology optimization process of the tool; a first vacuum port arranged at a first location on the first lateral portion; and a second vacuum port arranged at a second location on the first lateral portion, wherein the first vacuum port and the second vacuum port provide access to a vacuum pump to provide at least a partial vacuum to the top surface during composite part formation.

Abstract: A molding tool and method for making the molding tool by additive manufacturing is provided. The molding tool includes a tool body having a tooling surface for molding a part, the tool body comprising a eutectic alloy. The method for making the molding tool by additive manufacturing includes forming a first layer of eutectic alloy, the forming comprising depositing the eutectic alloy in liquid form and then cooling for form a solid eutectic alloy; forming an additional layer of the eutectic alloy on the first layer, the forming of the additional layer comprising depositing the eutectic alloy in liquid form and then cooling to form the solid eutectic alloy; and repeating forming an additional layer of the eutectic alloy on the first layer, the forming of the additional layer comprising depositing the eutectic alloy in liquid form and then cooling to form the solid eutectic alloy, and repeating one or more times to form a structure comprising a tool body having a tooling surface.

Abstract: Methods and apparatus for tooling in layered structures for increased joint performance are disclosed. A disclosed example method includes placing a tool onto a first substrate to define an impression in the first substrate, curing the first substrate, removing the tool from the first substrate to define a joint interface corresponding to the impression, and coupling, at the joint interface, the first substrate to a second substrate.

Abstract: Methods and apparatus for tooling in layered structures for increased joint performance are disclosed. A disclosed example method includes placing a tool onto a first substrate to define an impression in the first substrate, curing the first substrate, removing the tool from the first substrate to define a joint interface corresponding to the impression, and coupling, at the joint interface, the first substrate to a second substrate.

Abstract: Methods and apparatus for tooling in layered structures for increased joint performance are disclosed. A disclosed example method includes placing a tool onto a first substrate to define an impression in the first substrate, curing the first substrate, removing the tool from the first substrate to define a joint interface corresponding to the impression, and coupling, at the joint interface, the first substrate to a second substrate.

Abstract: A molding tool and method for making the molding tool by additive manufacturing is provided. The molding tool includes a tool body having a tooling surface for molding a part, the tool body comprising a eutectic alloy. The method for making the molding tool by additive manufacturing includes forming a first layer of eutectic alloy, the forming comprising depositing the eutectic alloy in liquid form and then cooling for form a solid eutectic alloy; forming an additional layer of the eutectic alloy on the first layer, the forming of the additional layer comprising depositing the eutectic alloy in liquid form and then cooling to form the solid eutectic alloy; and repeating forming an additional layer of the eutectic alloy on the first layer, the forming of the additional layer comprising depositing the eutectic alloy in liquid form and then cooling to form the solid eutectic alloy, and repeating one or more times to form a structure comprising a tool body having a tooling surface.

Abstract: A tool for forming a composite part and a method of making the tool and the composite part are disclosed. The tool includes a top surface that supports the composite part during forming, the top surface comprising a first lateral portion and a second lateral portion arranged on either side of a central part contacting surface; a first integrated heat sink arranged on an opposite surface of the top surface, wherein a shape of the first integrated heat sink is based on a thermal topology optimization process of the tool; a first vacuum port arranged at a first location on the first lateral portion; and a second vacuum port arranged at a second location on the first lateral portion, wherein the first vacuum port and the second vacuum port provide access to a vacuum pump to provide at least a partial vacuum to the top surface during composite part formation.

Abstract: Methods and apparatus for tooling in layered structures for increased joint performance are disclosed. A disclosed example method includes placing a tool onto a first substrate to define an impression in the first substrate, curing the first substrate, removing the tool from the first substrate to define a joint interface corresponding to the impression, and coupling, at the joint interface, the first substrate to a second substrate.

Abstract: Disclosed herein is an additively manufactured multi-layered ballistic armor and a method of forming a multi-layered ballistic armor. The multi-layered ballistic armor includes a metal layer and a ceramic layer. The metal layer includes first mechanical interconnection features and a plurality of first pores. The ceramic layer includes second mechanical interconnection features configured to mechanically interconnect with the first mechanical interconnection features and a plurality of second pores.

Abstract: A system and method for mitigating thermal loading between engine exhaust structures having different coefficients of thermal expansion. The engine exhaust structure comprises a metallic duct portion, a ceramic duct portion, and a double bipod fitting joining the metallic duct portion to the ceramic duct portion. The double bipod fitting is capable of flexing and taking up the thermal expansion differences between the joined metallic and ceramic ducts across the full temperature spectrum that an engine exhaust structure will experience in service.

Abstract: A system and method for mitigating thermal loading between engine exhaust structures having different coefficients of thermal expansion. The engine exhaust structure comprises a metallic duct portion, a ceramic duct portion, and a double bipod fitting joining the metallic duct portion to the ceramic duct portion. The double bipod fitting is capable of flexing and taking up the thermal expansion differences between the joined metallic and ceramic ducts across the full temperature spectrum that an engine exhaust structure will experience in service.

Abstract: A bladder. The bladder includes a bladder wall include first dimensions. The bladder also includes a first port disposed in the bladder wall. The bladder also includes knitted seams stitched into a first pattern in the bladder wall. The first pattern is configured such that when the bladder wall is subjected to a compressive force, the bladder collapses into a first pre-determined shape that has second dimensions less than the first dimensions.

Abstract: Adaptive airfoils are disclosed. A disclosed example airfoil for use with a vehicle includes first and second skins at least partially defining an exterior of a vehicle, where the first skin includes first and second pivots, and where the second skin includes third and fourth pivots, a first arm extending between the first and third pivots, where the first arm is rotatable about the first and third pivots, a second arm extending between the second and fourth pivots, where the second arm is rotatable about the second and fourth pivots, and a closeout including fifth and sixth pivots rotatably coupled to the first and second skins, respectively.

Abstract: Adaptive airfoils are disclosed. A disclosed example airfoil for use with a vehicle includes first and second skins at least partially defining an exterior of a vehicle, where the first skin includes first and second pivots, and where the second skin includes third and fourth pivots, a first arm extending between the first and third pivots, where the first arm is rotatable about the first and third pivots, a second arm extending between the second and fourth pivots, where the second arm is rotatable about the second and fourth pivots, and a closeout including fifth and sixth pivots rotatably coupled to the first and second skins, respectively.