Abstract: A milling apparatus is provided for cutting desired contours into a workpiece. The apparatus comprises a head that moves relative to a workpiece in a direction of cut. Spindles are supported on the head for rotation about parallel spaced-apart spindle z axes and comprise respective rotary cutters adapted for use in machining operations. A rotary head positioner is configured to be operatively connected between the head and a milling machine and to rotate the head about a head axis. A stagger controller is connected to the rotary head positioner and is configured to provide a desired swath of a cut to be formed in a workpiece by rotating the head to set a corresponding spindle stagger angle value.

Abstract: A milling apparatus is provided for cutting desired contours into a workpiece. The apparatus comprises a head that moves relative to a workpiece in a direction of cut. Spindles are supported on the head for rotation about parallel spaced-apart spindle z axes and comprise respective rotary cutters adapted for use in machining operations. A rotary head positioner is configured to be operatively connected between the head and a milling machine and to rotate the head about a head axis. A stagger controller is connected to the rotary head positioner and is configured to provide a desired swath of a cut to be formed in a workpiece by rotating the head to set a corresponding spindle stagger angle value.

Abstract: A method for hybrid direct manufacturing is provided. The method involves depositing a foundation of material onto a substrate platform or base plate. The foundation serves as a foundation for a block of material (a monolith) to be welded thereon. Once the foundation is created, the monolith or block of material may be placed against the foundation. The foundation may be created such that its boundary matches with the boundary of the monolith that will be welded on top of the foundation. Next, the monolith is welded to the foundation using a high energy beam such as an electron beam. The method may also involve depositing a layer of material on or adjacent to the monolith.

Abstract: A method of manufacturing a composite structure by compacting layers of laminate material within a mold and then curing the layers of laminate material within the mold.

Abstract: A method for hybrid direct manufacturing is provided. The method involves depositing a foundation of material onto a substrate platform or base plate. The foundation serves as a foundation for a block of material (a monolith) to be welded thereon. Once the foundation is created, the monolith or block of material may be placed against the foundation. The foundation may be created such that its boundary matches with the boundary of the monolith that will be welded on top of the foundation. Next, the monolith is welded to the foundation using a high energy beam such as an electron beam. The method may also involve depositing a layer of material on or adjacent to the monolith.

Abstract: A method of manufacturing a composite structure by compacting layers of laminate material within a mold and then curing the layers of laminate material within the mold.