Abstract: The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness and at least one mesh. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh produces a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. The manufactured reference standard may replace more costly porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

Abstract: The invention relates to pseudo porosity standards, and methods for their manufacture and use, which substantially mimic the effect porosity has on ultrasonic sound as it passes through a composite laminate. An ultrasonic inspection reference standard for composite materials having porosity may include a member having at least one thickness and at least one mesh. The member may be manufactured from a fiber-free polymer resin using a stereo lithography process. Use of the mesh produces a standard which transmits ultrasonic energy, with the mesh scattering and attenuating the energy. The manufactured reference standard may replace more costly porous, fiber-reinforced, composite reference standards in the aircraft industry and in other non-aircraft applications.

Abstract: A part having an integrated, discrete component is produced by direct digital manufacturing and rapid, solid free-form fabrication techniques. A CAD file representing the part is modified to include an opening in the body of the part in which the component is to be inserted. The fabrication is performed by additive layering of a thermoplastic material, preferably using fused deposition modeling or stereolithography. The layering process is interrupted to allow the component to be inserted in the partially formed part, following which additional layers are added which secure the component in the part in place and complete the physical structure of the part.