Gm Global Technolgoy Operations, Inc.

Mansour Ashtiani-Zarandi

David Gerard Hlavaty

Jeffrey A Welch

Youssef Tishbi

The present invention provides an improved method for rapidly making an electrode for electrical discharge machining. According to the invention, a stereolithography process is used to make a cured resin model of the electrode and having a network of interconnected supporting members defining the shape of the electrode and leaving channels between the supporting members to drain away uncured resin from the model. After the model is fully cured and the uncured resin drained away, a slurry mixture of graphite and resin is infiltrated into the voids of the model. The resin is then heat cured so that the resin is burned away leaving the electrode of pure carbon. Alternatively, the graphite and resin mixture can be cured sufficiently to harden and then an electrically conductive metalized coating is applied on the outer surface.

Method for making an electrode for electrical discharge machining by use

A structural prototype of the component part is made by first creating a model of the part which is of cured resin and has a network of interconnected supporting members defining the shape of the part and leaving channels between the supporting members to drain away uncured resin from the model. A hardenable structural material is infiltrated into the channels of the model and cured so that the resin model has become reinforced to provide a structural model of the component part. The hardenable structural material may be a mixture of powdered graphite and resin which is cured by heat. The heat may be sufficient to both cure the hardenable structure material and burn away the cured resin of the model so that the component part is then comprised of the hardened structural material having a network of channels therein where the cured resin of the model has been burned away. The model can then be further strengthened by filling the network of channels with a suitable hardenable material. The method can also be used to make a mold to be used in making a molded component.

Rapid making of a prototype part or mold using stereolithography model

The method for making an energy absorbing panel comprises the steps of coating a stretchable lightweight fabric with resin, molding the resin coated fabric into a generally planar sheet having a plurality of spaced apart conical projections rising from the planar sheet, cutting the fabric to provide molded panels in a size and shape of the desired energy absorbing panel structure, cutting adhesive coated planar sheet material in a size and shape of the desired energy absorbing panel structure to provide interface panels, interleaving the molded panels and the adhesive coated interface panels to the desired thickness of the energy absorbing panel structure, and then curing the adhesive to attach the panels and thereby form the energy absorbing structure. Upon the imposition of a force against the energy absorbing structures, the resin rigidified projections collapse to absorb energy. The energy absorbing structure is mounted on a vehicle door above the arm rest and below the window opening between the door trim panel and the door inner panel to absorb energy in the event that the occupant contacts the door inner panel.

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Birmingham, MI, United States of America

Mansour Ashtiani-Zarandi