Hrl Laboratories, LLC

The Boeing Company

David Page

Christopher Stephen Roper

Zak C Eckel

Sophia Shu Yang

Eric C Clough

Jacob Michael Hundley

Randall C Schubert

Arun Muley

Charles Edward Kusuda

Alan Jon Jacobsen

William B Carter

Keith Y Chong

Christopher J Ro

Angela M Iler

Faizal K Barnes

A method of repairing a sandwich structure includes: removing a damaged portion of a core and a damaged portion of a first facesheet to form an open volume; filling the open volume with an ultraviolet-curable photomonomer; partially curing the ultraviolet-curable photomonomer to form a plurality of photopolymer waveguides by utilizing ultraviolet light; and arranging a replacement facesheet on the damaged portion of the first facesheet and over the photopolymer waveguides.

Method of repairing sandwich structure

Method of repairing sandwich structure and repaired sandwich structure

A method for repairing a composite structure. A damaged portion of a first facesheet of the structure is removed, forming a hole in the first facesheet. A damaged portion of the underlying core is removed to form a cavity in the sandwich. If the second facesheet is damaged, the damaged section is removed, and covered and sealed with a facesheet repair section. If the core material is an open-cell material, a dam is formed around the perimeter of the cavity, to act as a barrier between the cavity and the core material. The cavity is at least partially filled with a photomonomer resin, which then is illuminated through a mask with collimated light to form a truss structure in the cavity. Residual photomonomer resin is removed, and a facesheet repair section is bonded over the hole in the first facesheet.

Composite structure repair methods incorporating a lattice core material

A heat exchanger with non-circular tubes arranged in a louvered fashion. In one embodiment the tubes include a first plurality of hollow members extending in a first direction, a second plurality of hollow members extending in a second direction different from the first direction, and a third plurality of hollow members extending in a third direction different from the first direction and from the second direction, the hollow members of the first plurality of hollow members, the second plurality of hollow members, and the third plurality of hollow members intersecting at a plurality of hollow nodes.

Louvered elliptical tube micro-lattice heat exchangers

A formation assembly for use in manufacturing a reinforced insulation panel including a foam material and a reinforcing structure includes a back plate including a first surface configured to receive the foam material, and a first support sheet spaced from the first surface to form a gap therebetween, wherein the first support sheet supports the reinforcing structure. The formation assembly also includes a second support sheet spaced from the first support sheet, wherein the second support sheet defines an upper boundary of the reinforced insulation panel. A rigid structure is coupled to the second support sheet, wherein the rigid structure restricts movement of the reinforced insulation panel.

Mechanically reinforced foam insulation panel and methods of making the same

A method of manufacturing a heat exchanger including a heat exchanger core of a first material, the method including additive manufacturing a sacrificial scaffold of a second material, the sacrificial scaffold corresponding in shape to that of the heat exchanger core, coating the sacrificial scaffold with a layer of the first material, and removing the sacrificial scaffold to leave behind the heat exchanger core with an integrated self-aligned passage.

Heat exchangers made from additively manufactured sacrificial templates

A system and method for forming microlattice structures of large thickness. In one embodiment, a photomonomer resin is secured in a mold having a transparent bottom, the interior surface of which is coated with a mold-release agent. A substrate is placed in contact with the top surface of the photomonomer resin. The photomonomer resin is illuminated from below by one or more sources of collimated light, through a photomask, causing polymer waveguides to form, extending up to the substrate, forming a microlattice structure connected with the substrate. After a layer of microlattice structure has formed, the substrate is raised using a translation-rotation system, additional photomonomer resin is added to the mold, and the photomonomer resin is again illuminated through the photomask, to form an additional layer of microlattice structure. The process is repeated multiple times to form a stacked microlattice structure.

Stacked microlattice materials and fabrication processes

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Malibu, CA, United States of America

David Page