Divergent Technologies, Inc.

Faraday & Future Inc.

Eahab Nagi El Naga

Antonio Bernerd Martinez

Broc William TenHouten

John Russell Bucknell

Kevin Robert Czinger

David Brian TenHouten

Muhammad Faizan Zafar

Chukwubuikem Marcel Okoli

Matthew Michael O'Brien

Thomas Samuel Bowden, Jr

Steven Blair Massey, Jr

Keith Allen Fleming

Zachary Meyer Omohundro

Narender Shankar Lakshman

Praveen Varma Penmetsa

Jon Paul Gunner

Richard Winston Hoyle

Oussama Rawas

William David Kreig

William Bradley Balzer

Alex James Hamade

John Franklin Dunham

Anil Paryani

Lukas Philip Czinger

Michael Thomas Kenworthy

Stuart Paul Macey

Matthew Cooper Keller

Chor Yen Yap

Alexander Pai-chung Teng

Roy Smith

Eli Rogers

Kenneth James Goodstein

William Alan Beverley

Justin David Almeleh

Matthew Coleman Tindall

Ross Harrison Byers

Boaz Jie Chai

Juan Cuauhtemoc Munoz

Jamison Van Bruch

Chukwubuikem Mercel Okoli

Broc William Tenhouten

Systems and methods of support structures in powder-bed fusion (PBF) are provided. Support structures can be formed of bound powder, which can be, for example, compacted powder, compacted and sintered powder, powder with a binding agent applied, etc. Support structures can be formed of non-powder support material, such as a foam. Support structures can be formed to include resonant structures that can be removed by applying a resonance frequency. Support structures can be formed to include structures configured to melt when electrical current is applied for easy removal.

Support structures in additive manufacturing

Aspects are provided relating to additive manufacturing. In one aspect, an apparatus for producing a three-dimensional (3D) structure is described that includes a build chamber having a top portion with windows through which radiative energy from one or more sources is provided to the build chamber to produce the 3D structure, and one or more manifolds disposed within the build chamber. The manifolds are configured to perform a gas exchange within the build chamber, and each manifold is positioned above a region where envelopes of radiative energy from the one or more sources overlap. In another aspect, the manifolds are moved to a first position adjacent to the top portion of the build chamber during a first mode of operation and moved to a second position away from the top portion of the build chamber during a second mode of operation.

3-D printer with manifolds for gas exchange

A multi-material three-dimensional (3-D) powder bed fusion-based (PBF) printer is disclosed. In one aspect, the 3-D PBF includes a body, a controller coupled to the body, a plurality of cartridges coupled to a print nozzle, an energy source coupled to an upper surface of the body, a deflector for deflecting an energy beam from the energy source, and a build plate on which a build piece can be 3-D printed. Each cartridge may include a slurry in which a specific print material or alloy is suspended. A depositor may selectively deposit the slurry onto the build plate to form a plurality of consecutive layers. For a given layer or a given region thereof, the controller may selectively deposit different amounts of the slurry to produce an alloy having a desired composition. A heating element may be used to vaporize the solvent in the deposited slurry. Using the deflector, the energy source can fuse the regions to sinter the deposited material and in some embodiments, to vaporize the solvent prior to sintering. In other embodiments, the slurries may include different alloys that can be selectively distributed across the layers to form a build piece having desired material characteristics.

Multi-material powder bed fusion 3-D printer

A three-dimensional (3-D) printer and technique for integrating additive and non-print manufacturing operations is disclosed. In an aspect, the 3-D printer includes an energy source and a powder bed regions for selectively fusing layers of a build piece. The 3-D printer further includes a robotic arm. The 3-D printing is interrupted responsive to instructions from a controller, upon which the robotic arm may perform one or more non-printing operations using the build piece such as milling, casting, molding, pressing, and the like. Following the non-printing operations, the 3-D printing operation continues, and a resulting assembly including the build piece is produced.

Three-dimensional printer and methods for assembling parts via integration of additive and conventional manufacturing operations

One aspect is an apparatus including an additively manufactured component including a surface with an end effector feature, the end effector feature co-additively manufactured with the additively manufactured component and configured to be gripped by a corresponding end effector on a robot. In an aspect, the end effector feature includes a recess in the surface. In another aspect, the recess includes an angled face. In an aspect, the recess has a teardrop shape. An aspect further includes an identification feature. In an aspect, the end effector feature includes a plurality of recesses in the surface. In another aspect, the end effector feature enables a 3-point kinematic self-aligning positive control lock.

End effector features for additively manufactured components

A high precision Interface Node is disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. The Interface Node may connect with another component or a Linking Node. The Interface Node is manufactured to achieve high precision functionality while enabling volume production. Current additive manufacturing technologies allow for the printing of high precision features to be manufactured, but generally this is performed at a slower rate. Consequently, in one aspect, the size of the Interface Nodes is reduced in order to overcome at least part of the slower production volume caused by creating the high precision Interface Nodes. The components and Linking Nodes to which the Interface Node is connected may only have basic features and functions. Accordingly, this latter category of components may use a high print rate and thus high production volume. In other embodiments, these low precision components may also be produced using a non-print manufacturing technology, such as casting, forging, etc., that may provide the requisite high throughput, or to high precision machined parts that lack the geometric flexibility of the Interface Node. In an embodiment, the Interface Nodes may be connected to other components via a Linking Node.

Structures and methods for high volume production of complex structures using interface nodes

Techniques for joining nodes and subcomponents are presented herein. An additively manufactured first node or subcomponent has a groove. An additively manufactured second node or subcomponent has a tongue configured to extend into and mate with the groove to form a tongue-and-groove connection between the first and second node or subcomponent. In some aspects, the tongue-groove connection may extend substantially around a periphery of the node or subcomponent. In other aspects, a first subcomponent having a fluid pipe interface may be coupled via a tongue-groove connection to a second subcomponent having a fluid pipe interface, thereby enabling fluid to flow between subcomponents of the resulting integrated component.

Systems and methods for implementing node to node connections in mechanized assemblies

An additively manufactured node is disclosed. A node is an additively manufactured (AM) structure that includes a feature, e.g., a socket, a receptacle, etc., for accepting another structure, e.g., a tube, a panel, etc. An additively manufactured node can include a surface with an opening to a feed channel through the node. A second surface of the node can include with a plurality of openings to an array of outlet channels. Each of the outlet channels can extend through the node and can connect to the feed channel. Tortuous paths can be used between channels created by the node surface and adjacent structures as well as node interior surfaces. These tortuous paths can be tuned to allow for optimal fluid flow processes.

Apparatus for injecting fluids in node based connections

A buffer block apparatus for securing a node may be described. The buffer block apparatus may include a first surface having disposed thereon at least one first zero-point feature configured for a first zero-point interface with a robotic assembly apparatus; and a second surface, different from the first surface, configured to connect with a first surface of a node and form a first rigid connection between the buffer block apparatus and the node, wherein the buffer block apparatus provides at least one reference coordinate system with respect to the node.

Buffer block apparatuses and supporting apparatuses

A node may be additively manufactured. The node may include a first surface and a second surface, and the second surface may bound a recess of the node. A structure may be inserted into the recess. A sealing member extend away from the second surface and contact the structure, such that a sealed space may be created between the node and the structure. An adhesive may be applied in the sealed space to at least partially attach the structure to the node.

Methods and apparatuses for sealing mechanisms for realizing adhesive connections with additively manufactured components

Systems, apparatus, and method for manufacturing a structure are disclosed. The structure includes a first portion, a second portion, and a structural joint. The apparatus is configured to receive instructions for printing the structural joint. The instructions are based on a data model of the structural joint. The apparatus is also configured to receive the first portion and the second portion, the first portion having a first conical tip and the second portion having a second conical tip. The apparatus is further configured to receive material. Additionally, the apparatus is configured to print the structural joint based on the instructions. The printing may include spray forming the material to produce the structural joint. The structural joint connects the first portion to the second portion.

Spray forming structural joints

A metal extrusion and nodes based structure is provided. The structure comprises one or more arc members connected by one or more node members, wherein the arc comprises (i) a wing feature which is configured to mate with one or more non-structural components, (ii) an internal passage feature which is configured to be inserted into a connecting feature of the corresponding node member, and (iii) one or more keying features formed from a mating interface with the corresponding node member.

Systems and methods for arc and node design and manufacture

Connections between nodes and tubes are provided. An apparatus can include additively manufactured first and second nodes, a tube, and an interconnect connecting the tube to the first and second nodes. An apparatus can include a node having an end portion with inner and outer concentric portions forming an annular gap therebetween, and a tube having an end portion extending into the gap.

Systems and methods for joining node and tube structures

Some embodiments of the present disclosure relate to an apparatus including an additively manufactured node having a socket. The apparatus includes a panel interconnected with node. The panel includes opposing surface layers and a core between at least a portion of the surface layers. The socket engages an end portion of the panel and shapes the surface layers on the end portion of the panel.

Interconnected deflectable panel and node

Apparatus and methods for sealing powder holes in additively manufactured parts are presented herein. Powder holes are co-printed to facilitate post processing sealing. Embodiments include co-printed caps, friction welded caps, rivets, silicone plugs, co-printed tangs, multiple micro holes, layup, and spin forming. By using one or more of the above techniques, powder holes can be sealed on additively manufactured parts.

Growing community of inventors

Topanga, CA, United States of America

Eahab Nagi El Naga