The Boeing Company

Hayden S Osborn

Nick Shabdeh Evans

Samuel F Harrison

Faraón Torres

Nick Shadbeh Evans

Ryan G Ziegler

Ciro J Grijalva, Iii

Alexander J Coco

Robert L Mann, Jr

Robert L Kearney

Karina R Lopez

Karina R Nipper

Michael T Hilliard

Faraòn Torres

Ciro J Grijalva

A system for separating support structure from a three-dimensional (3D)-printed component integrally printed with the support structure during an additive manufacturing (AM) process includes one or more transducers, indexing features configured to engage the transducer(s) and position the transducer(s) in contact with the support structure, and an electronic control unit (ECU). The ECU activates the transducer(s) which then vibrate at a predetermined resonant frequency of the support structure until the support structure fractures. A method includes engaging a transducer with an indexing feature, positioning the indexing feature with respect to the support structure such that the transducer is in contact with the support structure, and activating the transducer during a post-processing stage of the AM process, via the ECU, to cause the transducer to vibrate at the predetermined resonant frequency until the support structure fractures or breaks.

Resonant reactive support structure for additive manufacturing process

A laser assembly for additive manufacturing which includes a first laser beam aligned in a first direction and a first partial reflecting fixed mirror positioned aligned with the first direction which reflects a first portion of the first laser beam in a second direction and an exponentially reduced remaining second portion of the first laser beam passes through the first partial reflecting fixed mirror in the first direction. The laser beam assembly further includes a first oscillating mirror positioned aligned with the second direction of the first portion of the first laser beam wherein the first portion of the first laser beam is refracted by the first oscillating mirror in a third direction.

Laser fabrication additive system and method

A system for removing residual powder from a three-dimensional (3D)-printed component integrally constructed with a build plate during an additive manufacturing (AM) process includes an end-effector, an enclosure, one or more transducers, and an electronic control unit (ECU). The end-effector includes a base surrounded by a perimeter flange, and includes a through-opening that receives the build plate. A perimeter clamp attaches and seal the enclosure to a perimeter flange of the end-effector such that the enclosure, the base, and the build plate collectively form a powder containment cavity. The transducers vibrate at a predetermined frequency or range thereof. The ECU transmits a vibration control signal to the transducers during a post-processing stage of the AM process to loosen and remove the residual powder from the component and collect the loosened powder within the powder containment cavity.

Automated vibrational powder removal for additive manufacturing

A system for additively manufacturing a composite part comprises a delivery guide, movable relative to a surface. The delivery guide is configured to deposit at least a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and a thermosetting-resin component. The thermosetting-resin component comprises a first part and a second part. The non-resin component comprises a first element and a second element. The system further comprises a first resin-part applicator, configured to apply the first part to the first element, and a second resin-part applicator, configured to apply the second part to the second element. The system also comprises a feed mechanism, configured to pull the first element through the first resin-part applicator, to pull the second element through the second resin-part applicator, and to push the continuous flexible line out of the delivery guide.

Systems for additively manufacturing composite parts

A system for additively manufacturing a composite part is disclosed. The system comprises a delivery guide, movable relative to a surface. The delivery guide is configured to deposit at least a segment of a continuous flexible line along a print path. The print path is stationary relative to the surface. The continuous flexible line comprises a non-resin component and a thermosetting-epoxy-resin component that is partially cured. The system also comprises a feed mechanism, configured to push the continuous flexible line through the delivery guide. The system further comprises a cooling system, configured to maintain the thermosetting-epoxy-resin component of the continuous flexible line below a threshold temperature prior to depositing the segment of the continuous flexible along the print path via the delivery guide.

A system for additively manufacturing a composite part () comprises a delivery guide, movable relative to a surface. The delivery guide is configured to deposit at least a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and a thermosetting resin component that comprises a first part and a second part of a thermosetting resin. The print path is stationary relative to the surface. The delivery guide comprises a first inlet configured to receive the non-resin component, and a second inlet configured to receive at least the first part of the thermosetting resin. The delivery guide is further configured to apply the first part and the second part of the thermosetting resin to the non-resin component. The systemfurther comprises a feed mechanism, configured to push the continuous flexible line out of the delivery guide.

A method of additively manufacturing a composite part comprises depositing a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and further comprises a photopolymer-resin component that is uncured. The method further comprises delivering a predetermined or actively determined amount of curing energy at least to a portion of the segment of the continuous flexible line at a controlled rate while advancing the continuous flexible line toward the print path and after the segment of the continuous flexible line is deposited along the print path to at least partially cure at least the portion of the segment of the continuous flexible line.

Method for additively manufacturing composite parts

A system for additively manufacturing a composite part comprises a delivery assembly, a feed mechanism, and a source of curing energy. The delivery assembly comprises a delivery guide movable relative to a surface and is configured to deposit a continuous flexible line along a print path. The delivery assembly further comprises a first inlet, configured to receive a non-resin component, and a second inlet, configured to receive a photopolymer resin. The delivery assembly applies the photopolymer resin to the non-resin component. The feed mechanism pushes the continuous flexible line out of the delivery guide. The source of the curing energy delivers the curing energy to a portion of the continuous flexible line after it exits the delivery guide.

A system for additively manufacturing a composite part comprises a delivery guide and a surface, at least one of which is movable relative to another. The delivery guide is configured to deposit at least a segment of a continuous flexible line along a print path. The print path is stationary relative to the surface. The continuous flexible line comprises a non-resin component and a photopolymer-resin component that is partially cured. The system further comprises a feed mechanism configured to push the continuous flexible line through the delivery guide. The system further comprises a source of a curing energy. The source is configured to deliver the curing energy at least to a portion of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide.

A threaded adjustable-height insert may be installed in a bore of a sandwich panel, such that the insert may be configured to transfer a load to the sandwich panel. The threaded adjustable-height insert may include a first insert part and a second insert part that may be selectively operatively positioned with respect to each other. The overall height of the threaded adjustable-height insert may be adjusted by longitudinally sliding the second insert part with respect to the first insert part and rotating the second insert part with respect to the first insert part. Presently disclosed threaded adjustable-height inserts may be configured for flush installation in a sandwich panel. Methods of installing such threaded adjustable-height inserts and adjusting the height of the same are also disclosed.

Threaded adjustable-height inserts and related methods

A system comprises a delivery guide movable relative to a surface. The delivery guide is configured to deposit a continuous flexible line along a print path that is stationary relative to the surface. The system further comprises a vessel, configured to hold a volume of a liquid photopolymer resin and to apply a quantity of the liquid photopolymer resin to the non-resin component to create the continuous flexible line. The system further comprises a feed mechanism, configured to pull the non-resin component through the vessel and to push the continuous flexible line out of the delivery guide. The system further comprises a source of curing energy. The source is configured to deliver the curing energy at least to a portion of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide.

A system for additively manufacturing a composite part comprises a delivery guide, movable relative to a surface. The delivery guide is configured to deposit at least a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and a thermosetting-resin component. The thermosetting-resin component comprises a first part and a second part. The system further comprises a first resin-part applicator, configured to apply a first quantity of the first part to the non-resin component, and a second resin-part applicator, configured to apply a second quantity of the second part to the first quantity of the first part of a thermosetting resin, applied to the non-resin component. The system also comprises a feed mechanism, configured to pull the non-resin component through the first resin-part applicator and the second resin-part applicator, and to push the continuous flexible line out of the delivery guide.

A method of additively manufacturing a composite part comprises applying a liquid photopolymer resin to a non-resin component to create a continuous flexible line by pulling the non-resin component through a vessel, containing a volume of the liquid photopolymer resin. The continuous flexible line comprises the non-resin component and a photopolymer-resin component that comprises at least some of the liquid photopolymer resin applied to the non-resin component. The method further comprises routing the continuous flexible line into a delivery guide, pushing the continuous flexible line out of the delivery guide, depositing, via the delivery guide, a segment of the continuous flexible line along a print path, and delivering curing energy at least to a portion of the segment of the continuous flexible line.

Methods for additively manufacturing composite parts

A method of additively manufacturing a composite part is disclosed. The method comprises pushing a continuous flexible line through a delivery guide. The continuous flexible line comprises a non-resin component and a thermosetting-epoxy-resin component that is partially cured. The method also comprises depositing, via the delivery guide, a segment of the continuous flexible line along a print path. The method further comprises maintaining the thermosetting-epoxy-resin component of at least the continuous flexible line being pushed through the delivery guide below a threshold temperature prior to depositing the segment of the continuous flexible line along the print path.

A method of additively manufacturing a composite part is disclosed. The method comprises depositing a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and a thermosetting resin component that is not fully cured. The method further comprises, while advancing the continuous flexible line toward the print path, delivering a predetermined or actively determined amount of curing energy at least to a portion of the segment of the continuous flexible line at a controlled rate after the segment of the continuous flexible line is deposited along the print path to at least partially cure at least the portion of the segment of the continuous flexible line.

Growing community of inventors

Seattle, WA, United States of America

Hayden S Osborn