Ford Global Technolgoies, LLC

Ellen Lee

Siddharthan Selvasekar

Ching-Hung Chuang

Hongyi Xu

John Jeffrey Pfeiffer

Cynthia Mowery Flanigan

Kelly Ann Williams

David Douglas Friske

Dan Houston

A part formed by an additive manufacturing process consist of regions of voids, regions of solid material, and regions of non-uniform lattice cells, where each lattice cell includes bars. The regions are spatially distributed throughout the part as a function of load conditions such that the solid material is distributed in regions of first load paths and the non-uniform lattice cells are distributed in regions of second load paths lower in magnitude than the first load paths. Diameters of each bar of a non-uniform lattice cell are sized as a function of at least one of a resolution unit of the additive manufacturing process and part performance requirements. The diameters of the bars of the non-uniform lattice cells are classified into clusters with an average diameter size being assigned to all non-uniform lattice cells in the same cluster.

Integrated digital thread for additive manufacturing design optimization of lightweight structures

A part formed by an additive manufacturing process is provided, which consists of three (3) regions: regions of voids with no material; regions of solid material; and regions of non-uniform lattice cells. The regions are spatially distributed throughout the part as a function of load conditions such that the solid material is distributed in regions of first load paths and the lattice cells are distributed in regions of second load paths lower in magnitude than the first load paths. The lattice cells are tailored to the additive manufacturing process constraints and machine resolution.

An article includes a body that has a solid shell that encloses an interior region. The interior region has a solid sub-region, a lattice sub-region, and a hollow sub-region that are exclusive of each other and distributed based on load path. In an example, the article is a spoiler cap, such as for the spoiler on a vehicle.

Article with solid, lattice, and hollow sub-regions

A method for forming a molding compound including simultaneously chopping a non-synthetic reinforcement member and a synthetic reinforcement member and forming a hybrid reinforcement member from the chopped non-synthetic and synthetic reinforcement members. The hybrid reinforcement member can be molded into a molding compound.

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Ann Arbor, MI, United States of America

Ellen Lee