The present disclosure relates generally to apparatus and techniques in manufacturing, and more specifically to bridging of three-dimensional (3-D) printed components for use in producing vehicles, boats, aircraft and other mechanical structures.
Three-dimensional (3-D) printing, which may also be referred to as additive manufacturing, is a process used to create 3-D objects. The 3-D objects may be formed using layers of material based on digital model data of the object. A 3-D printer may form the structure defined by the digital model data by printing the structure one layer at a time. 3-D printed objects may be almost any shape or geometry.
A 3-D printer may disseminate a powder layer (e.g., powdered metal) on an operating surface. The 3-D printer may then bond particular areas of the powder layer into a layer of the object, e.g., by using a laser to bond the powder of the powder layer together. The steps may be repeated to sequentially form each layer. Accordingly, the 3-D printed object may be built layer by layer to form the 3-D object.
3-D printed components may be used to produce sub-components for various devices or apparatus. The 3-D printed sub-components may need to be attached or connected to other sub-components, including other 3-D printed sub-components, extruded sub-components, or still other sub-components. For example, one 3-D printed component may be used to bridge two or more other components together. The two or more other components may or may not be 3-D printed components.
Several aspects of apparatus for bridging will be described more fully hereinafter with reference to three-dimensional printing techniques.
One aspect is an apparatus including a node having a socket configured to receive a component and a detachable additively manufactured nozzle co-printed with the node and arranged for adhesive injection between the component and the socket.
Another aspect is an additively manufactured apparatus including a first additively manufactured component having an area configured to receive a second additively manufactured component. The first component includes an adhesive channel for injecting adhesive into the area when the second component is being connected to the first component.
Another aspect is an apparatus including a plurality of additively manufactured components each having an adhesive injection channel. The components are connected together such that adhesive injection channels are aligned to form an adhesive path that allows adhesive flow between the components.
Another aspect is a vehicle including a plurality of subassemblies, each of the subassemblies having a plurality of additively manufactured components each having an adhesive injection channel. The components for each of the subassemblies are connected together such that adhesive injection channels are aligned to form an adhesive path that allows adhesive flow between the components. Each of the subassemblies may be connected together such the adhesive path for each of the subassemblies are aligned to allow the adhesive to flow between the subassemblies.
It will be understood that other aspects of apparatus for bridging will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only several embodiments by way of illustration. As will be realized by those skilled in the art, the apparatus for bridging are capable of other and different embodiments, and its several details are capable of modification in various other respects, all without departing from the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
Various aspects of apparatus for bridging will now be presented in the detailed description by way of example, and not by way of limitation, in the accompanying drawings, wherein:
The detailed description set forth below in connection with the appended drawings is intended to provide a description of various exemplary embodiments of apparatus for bridging with 3-D printed components and is not intended to represent the only embodiments in which the invention may be practiced. The term “exemplary” used throughout this disclosure means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments presented in this disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that fully conveys the scope of the invention to those skilled in the art. However, the invention may be practiced without these specific details. In some instances, well-known structures and components may be shown in block diagram form, or omitted entirely, in order to avoid obscuring the various concepts presented throughout this disclosure.
The use of 3-D printing may provide significant flexibility for enabling manufacturers of mechanical structures and mechanized assemblies to manufacture parts with complex geometries. For example, 3-D printing techniques provide manufacturers with the flexibility to design and build parts having intricate internal lattice structures and/or profiles that may not be possible to manufacture via traditional manufacturing processes or may be cost prohibitive to manufacture via traditional manufacturing processes. As discussed above, the 3-D printed sub-components may need to be attached or connected to other sub-components, including other 3-D printed sub-components, extruded sub-components, or still other sub-components. Accordingly, one 3-D printed sub-component, extruded sub-component, or other sub-component may be used as a bridge to two or more other components. The bridge may be used to connect the two or more other components together. In an aspect, one or more of the other components may be 3-D printed sub-components, extruded sub-components, or still other sub-components.
In an aspect, one or more of the bridge components described herein and the two or more other components described herein may be dissimilar materials. Connections between dissimilar materials may lead to galvanic corrosion between the dissimilar materials. Accordingly, some aspects may include components that may block or decrease galvanic corrosion between the dissimilar materials. For example, some aspects may include one or more spacers, seals, inserts, gaskets, washers, linings, liners, or other blocking material between dissimilar materials. The one or more spacers, seals, inserts, gaskets, washers, linings, liners, or other blocking material may be configured such that the dissimilar materials do not come in contact with each other. Having spacers, seals, inserts, gaskets, washers, linings, liners, or other blocking material may prevent galvanic corrosion from occurring. Spacers, seals, inserts, gaskets, washers, linings, liners, or other blocking material may generally be applied to each example described herein, particularly examples that may include components of dissimilar materials.
Referring specifically to
In various embodiments, the deflector 105 can include one or more gimbals and actuators that can rotate and/or translate the energy beam source to position the energy beam. In various embodiments, energy beam source 103 and/or deflector 105 can modulate the energy beam, e.g., turn the energy beam on and off as the deflector scans so that the energy beam is applied only in the appropriate areas of the powder layer. For example, in various embodiments, the energy beam can be modulated by a digital signal processor (DSP).
In one aspect, the component 210 may be a shear plate. The shear plate may be inserted into the socket 214 on one side of the node 202. In an aspect, the node 202 may be an extrusion-like node 202. In other words, the node 202 may be the same or similar to a node that is extruded. For example, the node 202 may have a uniform cross section. In some aspects, the node 202, may be additively manufactured, rather than extruded.
In an aspect, the socket 212 may be a thinner socket, e.g., relative to the socket 214. The socket 212 may be on the other side of a node 202 from the socket 214. The socket 212 may attach to another, thinner panel, such as a metal sheet 206. In an aspect, the first socket may be located at one end of the node and the second socket may be located at an opposite end of the node. In an aspect, the node 202 may be elongated between the one end of the node and the opposite end of the node.
In an aspect, the metal sheet 206 may be supported by the first portion 204 of the node 202 and the component 210 may be supported by the second portion 208 of the node 202. In an aspect, the component 210 may be a metal component. In an aspect, the component 210 may be an additively manufactured component. In an aspect, the component 210 may be a panel. In an aspect, the node 202 may further include mass reduction feature such as an opening 216 located between the first socket 212 and the second socket 214. In an aspect, the node 202 may include a first section including the first portion 204 and a second section including the second portion 208. The first section may be interconnected with the second section.
In an aspect, the apparatus 200 may further include at least one of a spacer, a seal, an insert, a gasket, a washer, a lining, a liner, or a sealant between at least one of the first portion 204 and the metal sheet 206 or the second portion 208 and the component 210. The spacer, seal, insert, gasket, washer, lining, liner, or sealant may reduce galvanic corrosion by forming a gap between the at least one of the first portion and the metal sheet or the second portion and the component.
The node 302 may be made from steel or some other metal or combination of metals, e.g., an alloy. The metals or alloys used to make the node 302 may be metals or alloys of metals capable of being welded. In some examples, the node 302 may generally be the same or similar metal to the metal sheet 306. More particularly, the node 302 may generally be a metal that is capable of being welded to the metal of the metal sheet 306. In some examples, the node 302 and the metal sheet 306 may be different metals. The node 302 and the metal sheet 306 may generally be made from of metals or alloys that are compatible for welding. In other aspects, components may be fastened using one or more of welding, mechanical fastening, or adhesion.
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In an aspect, each of the one or more fasteners 410 may be a blind rivet (410). A blind rivet is a type of mechanical fastener that may be used to attach a first piece to a second piece. The first piece may be attached to the second piece using the blind rivet or multiple blind rivets. For each blind rivet, a first hole in the first piece and a second hole in the second piece may be aligned. The blind rivet may be introduced through the first hole and the through second hole. For example, the blind rivet may include a cylindrical barrel that may be passed through the aligned first and second holes. The blind rivet may also include a flange at a first end of said the cylindrical barrel for engaging the first piece to prevent further passage of said barrel through the aligned first and second holes. The blind rivet may also include a pin axially through the barrel having a head in external abutment with a second extremity of said barrel. The pin may be pulled through the barrel to engage with and deform the barrel
Blind rivets (410) may be printed into the node 402 so that the node 402 may be attached to the metal sheet 406. In an example, the co-printed blind rivets (410) may each include a barrel 412 that is part of the node 402. The blind rivets (410) may also each include a pin 414. The pin 414 may deform the barrel 412 to attach the metal sheet 406 to the node 402. In another aspect, the barrel may be co-printed as a separate part from the node 402, e.g., within a hole in the node 402.
Co-printing the node 402 to including additively manufactured fasteners (410), such as blind rivets, may allow for utilizing such fasteners (410) in locations in a node 402 that might not otherwise be accessible for such fasteners. For example, the example of
In an aspect, the first portion 504 of the node 502 may include a slot 512. The slot 512 may have a corrugated surface and a flat surface. In an aspect, the corrugation may be additively manufactured. For example, the slot 512 may be additively manufactured with the corrugation created during the additive manufacturing. In another aspect, the corrugation may be introduced by mechanical deformation in a post-processing. For example, the slot 512 may be additively manufactured and the corrugation may be created after the additive manufacturing. The flat surface may be opposite the corrugated surface. In an aspect, the apparatus 500 may further include an adhesive injection channel 514 for injecting adhesive into the slot 512. An adapter piece with a corrugated bottom and flat top may be printed to adhere to the top of corrugated metal sheet 506. Glue ports for adhesive may be printed into the adapter.
The node 702 may include a first section including the first portion 704 and a second section including the second portion 708. The first section may be interconnected with the second section. In an aspect, the first section, the second section, or both, may include a plurality of dovetail structures 710 and the other one of the first and second sections comprises a plurality of sockets 712 with each of the dovetail structures 710 located in a corresponding one of the sockets 712, e.g., when the metal sheet 706 and the node 702 are connected. In an aspect, the first section may be co-printed with the second section. In an aspect, the first section may be joined to the second section, e.g., by welding, such as when the node 702 and the metal sheet 706 are compatible metals for welding. In an aspect, the metal sheet 706 may be welded to the first portion 704 of the first section of the node 702.
For example, in an aspect, an aluminum node (702) may be inserted within a socket (712) in an aluminum extrusion and secured via welding. The aluminum node (702) may be attached to a steel node via multiple dovetail interconnects, e.g., without welding. In another aspect, the interface may either be welded, the two parts may be co-printed, or both. In an aspect, a steel node (702) may be welded to a piece of metal sheet (706), e.g., in addition to the dovetail interconnects. Alternatively, a combination of welds of compatible metals may be used with dovetail interconnects for weld incompatible metals to make any needed connections. In other aspects, components may be fastened using one or more of welding, mechanical fastening, or adhesion. Accordingly, needed connections may be made using one or more of welding, mechanical fastening, or adhesion.
In an aspect, the node 802 may further include a socket 812 having a plurality of protrusions 814. In an aspect, the apparatus 800 may further include the metal sheet 806 located in the socket 812. The metal sheet 806 may have a plurality of holes 816. Each of the protrusions 814 may extend through a corresponding one of the holes 816. In an aspect, at least one of the protrusions 814 may be stitch welded to an internal surface of the socket 811. In other aspects, components may be fastened using one or more of welding, mechanical fastening, or adhesion.
In an aspect, machine holes 816 may be drilled into a panel of one metal type. The panel may be inserted into a socket 812 within a node (802) of another metal type. The socket may contain intermittent protrusions 814. The protrusions 814 may be stitch welded together.
In an aspect, assembling the components further may include tack welding the components together. In an aspect, adhering the components together further may include curing the adhesive in an oven. In an aspect, dipping said at least a portion of the vehicle into a substance to prepare said at least a portion of the vehicle for painting might include dipping said at least a portion of the vehicle into a colloidal particle suspension in an electric field. In other aspects, components may be fastened using one or more of welding, mechanical fastening, or adhesion.
In an aspect, additively manufacturing the node (202, 302, 402, 502, 702, 802) includes additively manufacturing the first socket (212) located at one end of the node (202, 302, 402, 502, 702, 802) and the second socket (214) located at an opposite end of the node (202, 302, 402, 502, 702, 802). In an aspect, additively manufacturing the node (202, 302, 402, 502, 702, 802) includes additively manufacturing the node (202, 302, 402, 502, 702, 802) with an elongation between the one end of the node (202, 302, 402, 502, 702, 802) and the opposite end of the node (202, 302, 402, 502, 702, 802). In an aspect, additively manufacturing the node (202, 302, 402, 502, 702, 802) further includes additively manufacturing a mass reduction feature such as an opening (216) located between the first socket (212) and the second socket (214).
In an aspect, additively manufacturing the node (202, 302, 402, 502, 702, 802) includes additively manufacturing a first section including the first portion (204) and a second section including the second portion (208). The first section may be interconnected with the second section.
In an aspect, additively manufacturing one of the first and second sections includes additively manufacturing a plurality of dovetail structures (710) and wherein additively manufacturing the other one of the first and second sections includes additively manufacturing a plurality of sockets (712) with each of the dovetail structures (710) located in a corresponding one of the sockets (712).
In an aspect, additively manufacturing the first section and the second section includes co-printed the first section and the second section. In an aspect, additively manufacturing the node (302) further includes additively manufacturing the first portion (304) of the node (302) including a first weld protrusion (310) and a second weld protrusion (310).
In an aspect, additively manufacturing the node (402) further includes additively manufacturing the first portion (404) of the node (402) with one or more additively manufactured fasteners (410) co-printed with the node (402).
In an aspect, additively manufacturing the node (502) further includes additively manufacturing the first portion (504) of the node (502) with a slot (512) having a corrugated surface and a flat surface opposite the corrugated surface. In an aspect, additively manufacturing the node (802) includes additively manufacturing the node (802) with a socket (812) having a plurality of protrusions (814).
In an aspect, additively manufacturing the node (502) further includes adding or including at least one of a spacer, a seal, an insert, a gasket, a washer, a lining, a liner, or a sealant between at least one of the first portion 204 and the metal sheet 206 or the second portion 208 and the component 210. The spacer, seal, insert, gasket, washer, lining, liner, or sealant may reduce galvanic corrosion by forming a gap between the at least one of the first portion and the metal sheet or the second portion and the component.
At block 1004, manufacture the component supported by the second portion of the node. For example, manufacture the component supported by the second portion (208, 308, 408, 508, 708, 808) of the node (202, 302, 402, 502, 702, 802). In an aspect, the component may be a metal component. In an aspect, manufacturing the component may include additively manufacturing the component. In an aspect, the component may be a panel.
At block 1006, the component may be coupled to the node. For example, the component (210) may be coupled to the node (202).
At block 1008, the first section may be joined to the second section, e.g., by welding the metal sheet to the first portion (204, 304, 404, 504, 704, 804) of the first section of the node (202, 302, 402, 502, 702, 802), stitch weld at least one of the protrusions (814) to an internal surface of the socket (812), or weld the metal sheet to the node (302) at the first and second weld protrusions (310). In other aspects, components such as the first section and the second section may be fastened using one or more of welding, mechanical fastening, or adhesion.
At block 1010, locate the metal sheet in the socket, the metal having a plurality of holes with each of the protrusions extending through a corresponding one of the holes. For example, locate the metal sheet (806) in the socket (812), the metal sheet (806) having a plurality of holes (816) with each of the protrusions (814) extending through a corresponding one of the holes (816).
At block 1012, inject adhesive into the slot. For example, adhesive may be injected into the slot (512).
In an aspect, each of the one or more fasteners includes a blind rivet or other joining techniques such as pins, screws, adhesives, or other techniques used to join two or more components.
The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these exemplary embodiments presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be applied to apparatus for bridging with 3-D printed components. Thus, the claims are not intended to be limited to the exemplary embodiments presented throughout the disclosure but are to be accorded the full scope consistent with the language claims. All structural and functional equivalents to the elements of the exemplary embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. § 112(f), or analogous law in applicable jurisdictions, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”