Abstract: An open cell or highly porous woven composite truss utilizes fibers of carbon, glass, ceramic, or the like that are woven together in a loom. The warps or tow are woven with the wefts, while the fibers are impregnated with resin. The resin impregnation step may be performed before or after the weaving step. The truss is then cured on the loom and later may be machined as needed. A rigid foam material may be used to stabilize the shape of the truss prior to curing and while machining. The foam may be later chemically dissolved or otherwise disposed of.

Abstract: The present invention provides a direct manufacturing process operable to fabricate three-dimensional physical objects. These three-dimensional physical objects have improved mechanical properties over existing direct manufactured objects. The direct manufacturing process includes an extrusion process, a polymer application process, and a solidification process. The extrusion process deposits a thermoplastic polymer in a series of sequential layers wherein the series of sequential layers are deposited in predetermined patterns. The polymer application process applies compatible polymer(s) after the deposition of each thermoplastic layer. The compatible polymer may be applied in a same or different predetermined pattern when compared to that of the previously deposited thermoplastic layer. The compatible polymer diffuses into voids within the thermoplastic layer.

Abstract: An anisotropic carbon alloy (ACA) is formed from various carbon allotropes such as SWCNT, fullerenes, MWCNT, diamond-like carbon, diamond, nanocrystalline diamond, diamondoids, amorphous carbon, graphitic polyhedral crystals, graphite, graphene, HOPG, and hydrogenated amorphous carbon. The SWCNTs are present in different morphologies such as ropes, bundles, single filaments, tangled webs, etc. The SWCNT have large aspect ratios and weave throughout the ACA. By orienting or aligning the SWCNTs, directional physical properties of the SWCNTs may be observed in the ACA. Many morphologies of ACA are possible with a range of properties attainable as a function of the composition of carbon allotropes and post-processing techniques. Post-processing, such as annealing, can be done to further enhance particular properties of the ACA.

Abstract: The present invention provides fabrics that have unique mechanical, chemical, electrical, and thermal properties. The fabrics comprise layers of woven, knit or felted fibers, yarns or tow. Interstitially synthesized nanotubes, such as single-walled or multi-walled carbon nanotubes, enhance the fabric's antiballistic properties. These nanotubes may also insulate, semi-conduct or super-conduct electrical charges, or provide enhanced thermal properties of these fabrics which can be layered to form unique garments or structures.

Abstract: A high efficiency heat transfer device utilizes carbon nanotube deposits that are formed directly on the outer surface of the device to replace conventional cooling fins. A catalyst is used to facilitate retention of the nanotubes on the device before they are deposited. In addition, the nanotubes are infused with a protective outer layer, such as silicon. The protective layer penetrates the deposition, fills-in the voids between nanotubes, and then deposits on the surface of the nanotubes layer.

Abstract: An apparatus and method for fabricating corrugated composite stiffeners provides a base tool having grooves formed in an outer surface and a roller having a rotating shaft and a removable, lobed, elastomeric member surrounding the shaft. The lobes of the elastomeric member form a radial array around the shaft and match the contours of the grooves in the base tool. A section of prepreg fabric is placed between the roller and the base tool, and the roller is rotated to sequentially engage the lobes with the grooves, the lobes pressing the fabric into the grooves, the fabric conforming to the contours of the grooves. Several layers of fabric are applied, then the elastomeric member is released from the shaft, laid out flat, and placed on the fabric on the base tool, the lobes locating in the grooves. The base tool, fabric, and elastomeric member are enclosed in a vacuum bag and heated to cure the fabric.