The Boeing Company

Northrop Grumman Systems Corporation

General Nano LLC

Daniel Joseph Braley

John Huntley Belk

Elaine MacDonald

Zeaid F Hasan

Brandon Heath Wegge

Daniel R Ferriell

Jacob I Battat

Justine M Truscello

Minas Hagop Tanielian

Eric G Barnes

Stephen R Heinz

Russell W Cochran

Jade M Brown

Joseph B Harriman

Peter A Wilson

Brett Ian Lyons

Manny S Urcia

Eric Eldon Deck

Pedro A Gonzalez

Ronald O Lavin

Larry Allen Christy

Joseph E Sprengard

Andrew Lawrence Bauer

Nicole Renee Williams

Thomas Joseph Gonze

Trevor E Tucker

Anthony M Tamayo

Garrett B Peters

Janet Mary Wick

Andrew Pfeiffer

Elaine Macdonald

Nicole R Williams

Janet M Wick

Thomas J Gonze

Janice L Karty

A method of making an object through investment casting includes additively manufacturing a mold for the object with a printing head on a carriage supported by a frame with the mold being additively manufactured from multiple layers on a build platform supported by the frame. An interior surface of the mold is machined with a machining device on the carriage after a predetermined number of layers have been added to the mold through additive manufacturing. The object is investment cast by directing a casting material into the mold while the mold is supported by the build platform.

System and method for investment casting an object

A system for spraying a coating material to a substrate includes an optical sensor that monitors a thickness, a controller that generates a first signal corresponding to an amount of gas propellant to be heated, a second signal corresponding to a temperature to which the gas propellant is to be heated, a third signal corresponding to an amount of a solid powder composition to be mixed with the heated gas, and a fourth signal corresponding to a distance between the nozzle and the substrate, a first regulator that supplies an amount of gas propellant corresponding to the first signal, a heater that heats the gas propellant to the temperature corresponding to the second signal, a second regulator that supplies an amount of solid powder composition corresponding to the third signal, and an actuator that moves the nozzle corresponding to the fourth signal.

Method and system for fabricating an electrical conductor on a substrate

An article comprising additively manufactured metal portions is described. The article comprises a first additively manufactured metal portion, and a second additively manufactured metal portion coupled to the first additively manufactured metal portion at a welded joint. The article further comprises a resistive heating material disposed within an interior of the welded joint, the resistive heating material comprising a different material than the first additively manufactured metal portion and the second additively manufactured metal portion.

Article comprising additively manufactured metal portions

A powder-deposition apparatus for an additive manufacturing system includes a recoater, a mixer, and a powder feeder. The recoater is configured to discharge powder such that a powder layer is formed from the powder. The mixer is configured to mix a plurality of powder constituents to produce the powder and to dispense the powder to the recoater. The powder feeder is configured to selectively dispense a mass of each one of the plurality of powder constituents to the mixer such that a composition of the powder is selectively controlled.

System and method for additively manufacturing an object

A method of additively manufacturing an object includes successively forming a plurality of powder layers by depositing powder over a build platform using a powder-deposition apparatus. The method also includes successively forming a binder shell by bonding select regions of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers using a binder-delivery apparatus. The binder shell encloses a portion of the powder. The method further includes densifying the portion of the powder bound by the binder shell using a consolidation apparatus.

Method for additively manufacturing an object and additively manufactured object

A method of additively manufacturing an object includes steps of: (1) selectively depositing build powder inside of a build contour of the object to form a build-powder section of a powder layer; and (2) selectively depositing support powder outside of the build contour to form a support-powder section of the powder layer. According to the method, the build powder includes a build-powder composition, the support powder includes a support-powder composition, and the build-powder composition and the support-powder composition are different.

A method of additively manufacturing an object includes steps of: (1) successively forming a plurality of powder layers by depositing powder; (2) selectively controlling a composition of the powder that forms each one of the plurality of powder layers; and (3) successively forming a plurality of object layers of the object by joining the powder of a portion of each one of the plurality of powder layers before forming each successive one of the plurality of powder layers.

A method for fabricating an electrical conductor on a substrate by cold spraying includes propelling a solid powder composition that includes copper and highly oriented pyrolytic graphite using a gas propellant, and directing the solid powder composition towards the substrate at a velocity sufficient to cause the solid powder composition to undergo plastic deformation and to adhere to the substrate to deposit the electrical conductor thereon.

Methods of improving a surface finish of a casting pattern for an investment casting process, methods of forming an investment casting, and smoothed casting patterns. The methods for forming the casting patterns having an improved surface finish include sealing the casting pattern with a first coating material to form a sealed casting pattern and smoothing the sealed casting pattern with a second coating material to form a smoothed casting pattern. The methods for forming the investment casting include covering a smoothed casting pattern with a mold material to define an enclosed mold volume, curing the mold material to form a cured mold material, flowing the smoothed casting pattern from the enclosed mold volume to define a void space, filling the void space with a liquid investment casting material, and solidifying the liquid casting material to define an investment casting.

Methods and systems for improving a surface finish of an investment casting

A carbon nanomaterial composite sheet and a method for making a carbon nanomaterial composite sheet may include a layer of a carbon nanomaterial structure being bonded to a carrier layer, the carrier layer being fabricated from a porous metalized nonwoven material.

Carbon nanomaterial composite sheet and method for making the same

A method for making a conductive pre-impregnated composite sheet includes the steps of joining a nanomaterial composite sheet, a fiber-reinforcing sheet and a resin system to form a combined sheet, heating the combined sheet, compacting the combined sheet, and cooling the combined sheet to form conductive pre-impregnated composite sheet including the fiber-reinforcing sheet, and the nanomaterial composite sheet coupled to the fiber-reinforcing sheet, wherein the fiber-reinforcing sheet and the nanomaterial composite sheet are embedded in the resin system.

Conductive pre-impregnated composite sheet and method for making the same

Elongated, ultra-high conductivity electrical conductors for use in advanced electronic components and vehicles, and methods for producing the same, are disclosed herein. The elongated electrical conductors include a conductor body that defines a longitudinal axis. The conductor body includes an isotropically conductive matrix material and a plurality of anisotropically conductive particles interspersed within the isotropically conductive matrix material. Each anisotropically conductive particle defines a respective axis of enhanced electrical conductivity that is aligned with the longitudinal axis of the conductor body. The methods include providing a bulk matrix-particle composite that includes the isotropically conductive matrix material and the plurality of anisotropically conductive particles. The methods further include forming the bulk matrix-particle composite into an elongated electrical conductor and aligning the plurality of anisotropically conductive particles such that the respective axis of enhanced electrical conductivity thereof is at least substantially aligned with the longitudinal axis of the elongated electrical conductor.

Method for producing an ultra-high conductivity electrical conductor

Core structures () for composite panels () of an aircraft (), composite panels () and aircraft () including the core structures (), and methods () of manufacturing the composite panels () are disclosed herein. The core structures () include a first side (), a second side (), and a connecting region () that interconnects an upper portion () of the first side () with an upper portion () of the second side (). The first side (), the second side (), and the connecting region () at least partially define an antenna housing (), which defines a housing volume () configured to contain an aircraft antenna () of the aircraft (), and an electromagnetic wave transmission region () configured to permit electromagnetic waves to pass therethrough. The electromagnetic wave transmission region () defines a plurality of kite-shaped voids () arranged in a repeating pattern and bounded by a corresponding plurality of walls (), at least 10% of which extends at least substantially perpendicular to a surface () that bounds the electromagnetic wave transmission region ().

Core structures for composite panels of an aircraft, composite panels and aircraft including the core structures, and methods of manufacturing the composite panels

A transmission cable may include a conductor core, an insulator layer surrounding the conductor core, and a shielding layer surrounding the insulator layer, wherein the shielding layer includes a carbon nanotube sheet material.

Growing community of inventors

St. Peters, MO, United States of America

Daniel Joseph Braley