Honeywell Federal Manufacturing & Technologies, LLC

Gregory John Vernon

John Porter

Christian G Barr

Ben Brown

Rachel Cramm Horn

A system for creating an internal formation of a tubular structure having an inner surface via additive manufacturing. The system broadly includes a computer modeling system and an additive manufacturing system. The computer modeling system may include a processor for generating a lattice cellular component via computer-aided design software according to inputs received from a user. The processor may also generate an internal formation lattice structure based on the lattice cellular component and modify the lattice structure to follow and/or conform to the curvature of the inner surface of the outer wall of the tubular structure. The additive manufacturing system may be configured to produce the lattice structure and the tubular structure via additive manufacturing material deposited layer by layer according to the lattice structure.

System, method, and computer program for creating an internal conforming structure

A system and method of creating a lattice structure for a part formed via additive manufacturing. The method includes generating a finite element mesh including a first finite element, generating a first natural space data structure such that the first finite element includes the first natural space data structure, generating a first unit cell corresponding to the first finite element, and generating a first design space data structure such that the first unit cell includes the first design space data structure and the first natural space data structure. The method further includes modifying the first unit cell via the first design space data structure and modifying the first unit cell via the first natural space data structure to correspond to the modifications of the first unit cell in the first design space data structure.

System and method for creating lattice structures

A multi-layer armor plate comprises a strike plate, a structural mesh layer, an outer skin, a compliant mesh layer, and an inner skin layer. The strike plate has an outer surface and an inner surface. The structural mesh layer is positioned on the outer surface of the strike plate and includes lattice structure with a first structural compliance. The outer skin layer is positioned over the structural mesh layer. The compliant mesh layer is positioned on the inner surface and includes lattice structure with a second structural compliance that is greater than the first structural compliance. The inner skin layer is positioned over the compliant mesh layer.

Multi-layer wearable body armor

A system and method of creating a shape-conforming lattice structure for a part formed via additive manufacturing. The method includes receiving a computer model of the part and generating a finite element mesh. A lattice structure including a number of lattice cellular components may also be generated. Some of the mesh elements of the finite element mesh may be deformed so that the finite element mesh conforms to the overall shape of the part. The lattice structure may then be deformed so that the lattice structure has a cellular periodicity corresponding to the finite elements of the finite element mesh. In this way, the part retains the benefits of its overall shape and the benefits of lattice features without introducing structural weak points, directional stresses, and other structural deficiencies.

System, method, and computer program for creating geometry-compliant lattice structures

A method of generating a tessellated output file comprising receiving a computer-aided design (CAD) model file defining a CAD model including a plurality of vertices, a plurality of curves, a plurality of surfaces, and at least one volume; generating base polygon data defining the CAD model for additive manufacturing, the base polygon data including a plurality of connected polygons, each polygon including a plurality of nodes, a plurality of edges, and a face; generating data for a vertex metadata container including a listing of CAD model vertices and one polygon node associated with each CAD model vertex; generating data for a curve metadata container including a listing of CAD model curves and at least one polygon edge associated with each CAD model curve; and generating data for a surface metadata container including a listing of CAD model surfaces and at least one polygon face associated with each CAD model surface.

Computer-aided design file format for additive manufacturing and methods of file generation

A tessellated output file format describing a computer-aided design (CAD) model including a plurality of vertices, a plurality of curves, a plurality of surfaces, and at least one volume, the tessellated output file format comprising base polygon data, a vertex metadata container, a curve metadata container, and a surface metadata container. The base polygon data defines the CAD model for additive manufacturing and includes a plurality of connected polygons, each polygon including a plurality of nodes, a plurality of edges, and a face. The vertex metadata container includes a listing of CAD model vertices and one polygon node associated with each CAD model vertex. The curve metadata container includes a listing of CAD model curves and at least one polygon edge associated with each CAD model curve. The surface metadata container includes a listing of CAD model surfaces and at least one polygon face associated with each CAD model surface.

A system and method for generating a computer-based united cellular lattice structure includes dividing a part volume into a number of adjacent subvolumes each having a side combination corresponding to a number and orientation of adjoining sides and non-adjoining sides. A modified lattice cell may be generated from a base lattice cell for each side combination of the subvolumes such that each modified lattice cell has face surfaces on faces thereof corresponding to non-adjoining sides and does not have face surfaces on faces thereof corresponding to adjoining sides. Copies of the modified lattice cells may then be generated and inserted into corresponding subvolumes such that the faces of the modified lattice cell copies having face surfaces are positioned along non-adjoining sides of the subvolumes and faces of the modified lattice cell copies not having face surfaces are positioned along adjoining sides of the subvolumes.

System, method and computer program for creating united cellular lattice structure

A method for generating a computer-based united cellular lattice structure includes dividing a part volume into a number of adjacent subvolumes each having a side combination corresponding to a number and orientation of adjoining sides and non-adjoining sides. A modified lattice cell may be generated from a base lattice cell for each side combination of the subvolumes such that each modified lattice cell has face surfaces on faces thereof corresponding to non-adjoining sides and does not have face surfaces on faces thereof corresponding to adjoining sides. Copies of the modified lattice cells may then be generated and inserted into corresponding subvolumes such that the faces of the modified lattice cell copies having face surfaces are positioned along non-adjoining sides of the subvolumes and faces of the modified lattice cell copies not having face surfaces are positioned along adjoining sides of the subvolumes.

System, method, and computer program for creating united cellular lattice structure

A system and method for improving the production of objects with fully defined CAD models by generating CAD slice files from the native CAD geometries for use by AM machines. An electronic processing element receives the CAD model having a native and/or neutral format with metadata, determines a desired resolution, slices the CAD model to create the slice files having a slice format (e.g., point, edge, surface, volume) and retaining the metadata, and evaluates the slice files to determine whether the resolution has been achieved. If so, the slice files are sent to the AM machine. If not, a new desired resolution is determined and the CAD model is re-sliced, which may include combining the slice files to regenerate the CAD model. A support structure for the object may be analyzed, and if distortion is predicted, a modified CAD model may be created and sliced to create modified slice files.

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Kansas City, MO, United States of America

Gregory John Vernon