The Boeing Company

Polymer Group, Inc.

Theboeing Company

Michael William Hayes

John Cleveland Waldrop, Iii

Matthew Scott Thompson

Michael H Johnson

Olaf Erik Alexander Isele

Rajeev Chhabra

Han Xu

Savas Aydore

Loren J Strahm

Zachary Benjamin Renwick

Timothy Krause

Daniel David Bloch

David Michael Dietrich

Gregory James Schoepen Hickman

Peter A Szostak

Manny S Urcia

Nathanial C Cuddy

Eric Herrera

Keith Allan Etling

Gregg Robert Bogucki

Stephen R Heinz

Brandon L Bertolucci

Jordan Kreitzman

Andrews Guadron

Olaf Erik Isele

John E Inman

John G Macke, Jr

Daniel E Muntges

David M Baer

Rehan Kaluarachchi

Rehan Milarachi

John C Waldrop

John C Waldrop Iii

John C Iii Waldrop

David M Deitrich

Gregory James Hickman

A flow path duct system for a propulsion system of an aircraft includes a base defining a flow surface. The base has an internal surface and an external surface. A plurality of perforations are formed through the base between the internal surface and the external surface. A plurality of supports define a plurality of cavities. The plurality of supports extend outwardly from the external surface of the of the base. One or more of the plurality of cavities are in fluid communication with the one or more of the plurality of perforations. A backing surface is secured to the plurality of supports. The plurality of supports are disposed between the base and the backing surface. The one or more of the plurality of cavities are in fluid communication with an internal volume defined by the internal surface of the base through the one or more of the plurality of perforations. The base, the plurality of supports, and the backing surface can be integrally formed together as a monolithic, load-bearing structure.

Propulsion flow path duct systems and methods

Systems and methods are provided for septa for acoustic cells. One embodiment is a method that includes fabricating a septum of a cell of an acoustic panel, by heating a material into a molten material, depositing the molten material to form a lower chamber of the septum that extends vertically upwards and includes an entry, iteratively depositing layers of the molten material, each layer comprising a filament at the entry that includes overhangs with respect to vertically adjacent layers, and forming openings at locations of the overhangs.

Additively manufactured septa for acoustic panels

Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.

System and method for cutting material in continuous fiber reinforced additive manufacturing

Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A composite feedstock strip may include continuous unidirectional fibers extending parallel to each other and to the principal axis of the strip. This fiber continuity yields superior mechanical properties, such as the tensile strength along strip's principal axis. Composite feedstock strips may be fabricated by slitting a composite laminate in a direction parallel to the fibers. In some embodiments, the cross-sectional shape of the slit strips may be changed by reattributing material at least on the surface of the strips and/or by coating the slit strips with another material. This cross-sectional shape change may be performed without disturbing the continuous fibers within the strips. The cross-sectional distribution of fibers within the strips may be uneven with higher concentration of fibers near the principal axis of the strips, for example, to assist with additive manufacturing.

Composite feedstock strips for additive manufacturing and methods of forming thereof

A fiber reinforced polymer part is fabricated by rastering a deposition head over a substrate, and additively forming part features by extruding a polymer having an entrained continuous reinforcement from the deposition head onto a substrate.

Extruded deposition of fiber reinforced polymers

A composite structure assembly includes a composite core including a flexible base and a plurality of cells extending from the flexible base. The composite core is conformable to different shapes. The plurality of cells are configured to move in response to movement of the flexible base. At least one of the plurality of cells may include a central column connected to a first flared end and a second flared end that is opposite from the first flared end.

Composite structure assembly having a conformable core

A composite structure assembly and method of forming a composite structure assembly is provided. The composite structure assembly includes a composite core including a first cell layer having a plurality of first cells and a second cell layer having a plurality of second cells. The first cell layer is adjacent to the second cell layer. The plurality of first cells are fluidly interconnected with the plurality of second cells.

Composite structure assembly having an interconnected layered core

Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A strip may include continuous fibers extending parallel to the principal axis of the strip. The cross-sectional distribution of these continuous fibers may be uneven. Specifically, the fibers may be concentrated near the center of the strip and may be positioned away from at least some portions of the strip surface. A strip may be formed by laminating a layup of one or more fiber-containing plies and one or more of resin plies. The position of the different types of plies in the layup is used to control distribution of the fibers and other materials within the strip. The laminated sheet is slit into multiple strips in a direction parallel to the continuous fibers. The cross-sectional profile of the slit strips may be later changed without disturbing orientation of the continuous fibers.

Sound damping structures and methods for additively manufacturing composite structures having sound damping properties. In some embodiments, sound damping structures may be manufactured according to methods that may include selecting a desired sound damping geometry, inputting a three-dimensional computer-aided design model of the geometry into an additive manufacturing machine, and additively manufacturing a three-dimensional sound damping structure corresponding to the computer-aided design model.

Geometric sound absorption via additive manufacturing

A computer implemented apparatus and method for receiving tool paths that a dispensing head follows to deposit roads of material for successively building object layers of a 3D object during an additive manufacturing process, generating simulated object layers of a simulated 3D object from the tool paths, wherein the simulated object layers represent an interior geometry of each one of the object layers, determining a contact surface area between adjacent ones of the simulated object layers, and determining a predicted mechanical property of the 3D object from the contact surface area and a material property of the material.

Apparatus and method to predetermine a mechanical property of a three-dimensional object built by additive manufacturing

Growing community of inventors

Belleville, IL, United States of America

Michael William Hayes