Divergent Technologies, Inc.

Jon Paul Gunner

Narender Shankar Lakshman

Antonio Bernerd Martinez

Broc William TenHouten

Kevin Robert Czinger

David Charles O'Connell

Stuart Paul Macey

John Russell Bucknell

Eahab Nagi El Naga

David Brian TenHouten

Thomas Samuel Bowden, Jr

Muhammad Faizan Zafar

Alex James Hamade

Richard Winston Hoyle

William David Kreig

Steven Blair Massey, Jr

Alexander Pai-chung Teng

Yong-Bae Cho

Ian Hawthorn Ashdown

Some embodiments of the present disclosure relate to an additively manufactured transport structure. The transport structure includes cavities into which components that use an external interface are inserted. A plurality of components are assembled and integrated into the vehicle. In an embodiment, the components and frame are modular, enabling reparability and replacement of single parts in the event of isolated failures.

Methods and apparatus for additively manufactured endoskeleton-based transport structures

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 providing universal interfaces between parts of a transport structure are disclosed. In one aspect of the disclosure, an apparatus for joining first and second parts of a transport structure includes an additively manufactured body having first and second surfaces. The first surface may connect to a first part such as, for example, a panel. The second surface may include a fitting for mating with a complementary fitting on a second part.

Methods and apparatuses for universal interface between parts in transport structures

Systems and methods for co-casting of additively manufactured, high precision Interface Nodes are disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. Co-casting of Interface Nodes by casting a part onto the Interface Node results in a hybrid structure comprising the cast part and the additively manufactured Interface Node. The interface node may include at least one of a node-to-tube connection, node-to-panel connection, or a node-to-extrusion connection. In an embodiment, engineered surfaces may be provided on the Interface Node to improve the blend between the Interface Node and the cast part during the co-casting process.

Systems and methods for co-casting of additively manufactured interface nodes

Systems and methods of co-printing a unitary hinge are provided. The unitary hinge may be co-printed using an additive manufacturing process. The unitary hinge includes a hinge pin that is substantially cylindrical in shape. The unitary hinge also includes a knuckle which surrounds a portion of the hinge pin and is configured to be manipulated about the hinge pin. The hinge pin is fabricated in situ with the knuckle such that further assembly is unnecessary. The unitary hinge may also include retention mechanism to retain the hinge within the knuckle without substantially restricting the knuckle from being rotated about the hinge pin. The unitary hinge may further be configured with a fluid port which may, for example, be used to provide a lubricant to an area between the hinge pin and the knuckle or to vacuum powder material or debris from the area.

Systems and methods for co-printed or concurrently assembled hinge structures

Techniques for flexible, on-site additive manufacturing of components or portions thereof for transport structures are disclosed. An automated assembly system for a transport structure may include a plurality of automated constructors to assemble the transport structure. In one aspect, the assembly system may span the full vertically integrated production process, from powder production to recycling. At least some of the automated constructors are able to move in an automated fashion between the station under the guidance of a control system. A first of the automated constructors may include a 3-D printer to print at least a portion of a component and to transfer the component to a second one of the automated constructors for installation during the assembly of the transport structure. The automated constructors may also be adapted to perform a variety of different tasks utilizing sensors for enabling machine-learning.

Robotic assembly of transport structures using on-site additive manufacturing

The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component.

Methods and apparatus for manufacturing optimized panels and other composite structures

Techniques for producing panels such as for use in a vehicle, boat, aircraft or other transport structure or mechanical structure using a 3-D-printed tooling shell are disclosed. A 3-D printer may be used to produce a tooling shell containing Invar and/or some other material for use in molding the panels. A channel may be formed in a 3-D printed tooling shell for enabling resin infusion, vacuum generation or heat transfer. Alternatively, or in addition to, one or more hollow sections may be formed within the 3-D printed tooling shell for reducing a weight of the shell. The panel may be molded using the 3-D printed tooling shell.

3D-printed tooling shells

Techniques for 3-D printing a tooling shell for use in producing panels for a transport structure, such as an automobile, boat, aircraft, or other vehicle, or other mechanical structure, are disclosed. A 3-D printer may be used to produce a tooling shell containing Invar and/or some other material for use in molding the panels. A channel may be formed in a 3-D printed tooling shell for enabling resin infusion, vacuum generation or heat transfer. Alternatively, or in addition to, one or more hollow sections may be formed within the 3-D printed tooling shell for reducing a weight of the shell.

3D-printed tooling and methods for producing same

Apparatus and methods for additively manufactured structures with augmented energy absorption properties are presented herein. Three dimensional (3D) additive manufacturing structures may be constructed with spatially dependent features to create crash components. When used in the construction of a transport vehicle, the crash components with spatially dependent additively manufactured features may enhance and augment crash energy absorption. This in turn absorbs and re-distributes more crash energy away from the vehicle's occupant(s), thereby improving the occupants' safety.

Apparatus and methods for additively manufactured structures with augmented energy absorption properties

An automated wrapping technique for vehicle components is disclosed. A component to be wrapped is secured to a fixture, which in turn is coupled to an actuator. A grabber arm grabs a length of wrap from a feed roll. The grabber arm removes the backing and spreads the wrap over the component. The actuator pushes the component upward until the wrap contacts the component surface. An applicator may concurrently smooth the wrap and evacuate trapped air. The wrap may be cut around the periphery of the component, and hemmed. A controller provides instructions to automate the wrapping mechanism.

Automated wrapping of components in transport structures

One aspect is an apparatus including an additively manufactured first component and a captive nut contained within the first component for interconnecting the first component to a second component. Another aspect is an apparatus including a first additively manufactured component having a hole and a second additively manufactured component having a socket. The apparatus further includes a pin having a head engaging a surface of the first component and a shaft extending from the head through the hole in the first component and into the socket of the second component. Another aspect is an apparatus including first and second panels. The apparatus also includes a bolt having a head and a shaft extending from the head and a nut located at a distal end of the shaft. The first and seconds panels may be sandwiched between the bolt and nut to interconnect the first and second panels.

Growing community of inventors

Palos Verdes Estates, CA, United States of America

Jon Paul Gunner