Abstract: A process for fabricating a curved beam including a micro-truss structure. In one embodiment, the process includes fabricating the micro-truss structure on a bottom facesheet, where the micro-truss structure is only partially cured so that it is readily bendable, and then forming the partially cured micro-truss structure and bottom facesheet over a curved fixture, where the partially cured micro-truss structure is then fully cured and hardened to its final curved state. A top facesheet is then adhered to a top surface of the micro-truss structure. In an alternate embodiment, a curved bottom facesheet is forced flat against a fixture and the micro-truss structure is formed while the bottom facesheet is secured to the fixture to a partially cured state. The bottom facesheet is then released from the fixture, which causes it to return to its curved configuration causing the micro-truss structure to bend.

Abstract: An energy absorber according to various embodiments can include a structure having a predetermined cross-sectional profile. A hollow profile is formed within the structure. The pre-determined cross-sectional profile of the structure is configured based on a deceleration-time profile that includes a first period and a second period. The first period is defined by a substantially sharp and linear increase in magnitude of the deceleration of an impact until a maximum deceleration value is achieved. The second period is defined by a rapid decrease in the magnitude of the deceleration.

Abstract: A cover covering an object includes an inner surface of the cover facing the object and spaced from the object, and an outer surface of the cover opposite the inner surface. A local energy absorber is operatively attached to the inner surface of the cover. The local energy absorber includes an energy absorbing core layer operatively attached to the inner surface of the cover and a frangible face sheet layer attached to the energy absorbing core layer facing the object. The frangible face sheet layer is to initiate fracture of the frangible face sheet layer during an impact applied to the outer surface defining an impact event having a duration of less than 20 milliseconds.

Abstract: A mold comprising a scaffolding support structure including a base member, a top member and side members defining an enclosure. The scaffolding structure further includes a plurality of interconnected and elongated support members interspersed within the enclosure between the base member and the top member so as to define open space within the enclosure for ease of heating and cooling fluid flow, and a plurality of flow partitions within the enclosure. An intermediate layer is formed on the top member and a working surface layer is formed on the intermediate layer.

Abstract: Methods for welding sandwich structures together, especially vehicle structures, where the structures include two opposing face sheets with a core, such as a micro-truss core, therebetween. In one embodiment, two sandwich structures are butt welded together. A cooling fluid barrier is provided at an end of the core between the face sheets to prevent cooling fluid from entering the core during the welding process, where the cooling barrier can be a micro-truss structure and can include cooling fluid channels. A welding insert is inserted into the end of one of the structures adjacent to the cooling barrier, and is welded to the other structure to secure the structures together.

Abstract: An approach to designing lightweight metal-polymer composite structures in a manner that decomposes the structure into at least two parts. In one specific embodiment, the approach is a manufacturing process for a vehicle that includes attaching an impact beam to a vehicle structure. The process includes providing a vehicle structure including a back plate of the impact beam being made of a suitable material, such as a metal, that can withstand high temperature processes. A front part of the impact beam including a front plate and a polymer core is attached to the back plate. The back plate is designed to provide structural integrity that allows the vehicle structure to go through the high temperature processes and/or the vehicle structure provides structural integrity that allows the back plate to go through the one or more processes. The back plate is also designed to provide desired functional characteristics of the beam.

Abstract: A vehicle structural member, such as a rocker panel, including a micro-truss core. The structural member includes specially configured and opposing outer panels that are welded together to define a channel therein, where the micro-truss core is placed in one of the panels or is fabricated to one of the panels during the micro-truss fabrication process before the panels are secured together. The micro-truss core can include separate individual sections, where each section has a tailored stiffness for that location in the member, or the micro-truss core can be a continuous core, where different sections along the length of the core are fabricated with different stiffnesses.

Abstract: Fixtureless self-alignment and orientation of components during an assembly process, and self-aligning/self-orienting components for assembly. Self-alignment and self-orientation are provided by integrating complementary spatially-modulated magnetic arrays into components requiring alignment and/or orientation during an assembly process. In addition to providing self-alignment/self-orientation, the spatially-modulated magnetic arrays also provide selective component placement and/or assembly order. Final assembly can involve permanent mechanical or adhesive fasteners.

Abstract: A method for providing localized stiffening of a vehicle trim panel using a plurality of discrete stiffening elements. The method includes selectively placing one or more of the discrete stiffening elements on the panel and then bonding the stiffening elements to the panel.

Abstract: A number of variations may include a panel comprising a skin and an interior wherein the interior comprises a microtruss.

Abstract: A product for sensing may include a non-conductive layer of a polymer that may be selected for its responsiveness to a stimulus from one of a selected analyte, or a selected group of analytes. The non-conductive layer may be non-conductive of an electrical current. A conductive layer may be in contact with the non-conductive layer and may be conductive of the electrical current. A lead for may provide an electric current to the conductive layer. A device may be provided to detect at least one property of the conductive layer in response to the stimulus.

Abstract: A process for reinforcing a trim panel for a vehicle using one or more micro-truss reinforcement patches. Each micro-truss reinforcement patch is secured to an inner surface of a show surface panel of the trim panel while it is in a partially cured state and then fully cured. The micro-truss patch is fusion bonded to the panel.

Abstract: A technique for providing localized stiffening of a vehicle trim panel, especially for high curvature areas. The vehicle trim panel includes an outer panel having an outer show surface and an inner surface. A plurality of discrete reinforcement elements are bonded to the inner surface of the outer panel at locations where localized stiffening is desired. The discrete elements can come in a variety of different shapes and sizes, where the combination of elements and the number of elements is selected for a particular trim panel stiffness.

Abstract: A method for securing sandwich structures together, especially vehicle structures. In one embodiment, two sandwich structures are perpendicularly secured together, where a first one of the sandwich structures includes a micro-truss core having one unit cell geometry and second one of the sandwich structures includes a micro-truss core having different unit cell geometry. The micro-truss core of the second sandwich structure includes a micro-truss extension fabricated at the same time as the micro-truss core and having the same unit cell geometry as the micro-truss core for the first sandwich structure. The extension is inserted in an open area between face sheets in the first sandwich structure so that it abuts against the micro-truss core in the first sandwich structure.

Abstract: A vehicle hood covering an underhood object includes an inner surface of the vehicle hood facing the underhood object and spaced from the underhood object, and an outer surface of the vehicle hood opposite the inner surface. A local energy absorber is operatively attached to the inner surface of the vehicle hood. The local energy absorber is a multiply-connected structure. The local energy absorber includes a wall defining an interior surface having symmetry about a central plane normal to the inner surface of the vehicle hood. A plurality of apertures is defined in the wall symmetrically about the central plane to initiate buckling and fracture in the wall during an impact applied to the outer surface defining an impact event having a duration of less than 20 milliseconds.

Abstract: A sealing assembly includes a door and a seal. The door includes a flexible body that is movable between an open position and a closed position. The seal is movable between an engaged position in which the seal is positioned in engagement with a portion of the flexible body when the flexible body is in the closed position and a disengaged position in which the seal moves away from the portion of the flexible body as the flexible body moves from the closed position to the open position such that the flexible body is spaced from the seal to minimize frictional engagement with the seal.

Abstract: A process for fabricating a curved vehicle impact sandwich beam including a micro-truss structure. The method includes positioning a mold in contact with a curved bottom facesheet so that the mold and the bottom facesheet define a reservoir. The reservoir is filled with a liquid photo-polymer resin and a mask is positioned over the reservoir. A series of UV light sources are provided on a mounting member relative to the mask and the mounting member is flexed to conform to the shape of the bottom facesheet. Light from UV sources shines through apertures in the mask to cure and form polymerized struts in the reservoir to define the micro-truss structure formed to the facesheet.

Abstract: An energy absorber according to various embodiments can include a structure having a predetermined cross-sectional profile. A hollow profile is formed within the structure. The pre-determined cross-sectional profile of the structure is configured based on a deceleration-time profile that includes a first period and a second period. The first period is defined by a substantially sharp and linear increase in magnitude of the deceleration of an impact until a maximum deceleration value is achieved. The second period is defined by a rapid decrease in the magnitude of the deceleration.

Abstract: An approach to designing lightweight metal-polymer composite structures in a manner that decomposes the structure into at least two parts. In one specific embodiment, the approach is a manufacturing process for a vehicle that includes attaching an impact beam to a vehicle structure. The process includes providing a vehicle structure including a back plate of the impact beam being made of a suitable material, such as a metal, that can withstand high temperature processes. A front part of the impact beam including a front plate and a polymer core is attached to the back plate. The back plate is designed to provide structural integrity that allows the vehicle structure to go through the high temperature processes and/or the vehicle structure provides structural integrity that allows the back plate to go through the one or more processes. The back plate is also designed to provide desired functional characteristics of the beam.

Abstract: A technique for welding two dissimilar metal panels or structures together, such as vehicle structures, by providing a sandwich structure between the dissimilar metal structures that includes one skin being made of the same metal as one of the metal structures and an opposing skin being made of the same metal as the other metal structure, and including an electrically non-conducting core between the skins.