Amazon Technologies, Inc.

Prescott Gee Glynn

Adrian Timothy Wallace

Steven McGinnis

Robert Todd Marks

Armando Medina Romero

Kader Chellabi

Mark Gerald Munster, Jr

Ricky Dean Welsh

Mark Gerald Munster

Lightweight and strong components having any desired shape, form, or geometry may be manufactured using thermally expanding mandrels by the processes described herein. A thermally expanding mandrel may be formed from an expanding material composition including thermally expanding particles, e.g., micronized rubber particles, and water-soluble binder material, e.g., gypsum plaster. Component material may be applied to the mandrel, and the mandrel may be inserted into a molding tool. Upon application of heat to the mandrel, the mandrel may expand, and compress and cure the component material into a component within the molding tool. Following formation of the component, the mandrel may be washed out of the component, e.g., using pressurized water, and the expanding material composition may be recycled and/or reused.

Thermally expanding mandrel for cast components

Lightweight and strong components may be manufactured using self-skinning foam material compositions by the processes described herein. One or more mandrels may be inserted into a molding tool, and a self-skinning foam material composition may be injected into the molding tool. After closing the molding tool, the self-skinning foam material composition may expand and cure to form a component, and one or more skins may be formed on exterior and/or interior surfaces of the component. For example, an external skin may be formed on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

Self-skinning cast components having negative space spars

Lightweight and strong components may be manufactured using foam material compositions and resin coating materials by the processes described herein. One or more mandrels and/or a molding tool may be coated with resin coatings, the one or more mandrels may be inserted into the molding tool, and a foam material composition may be injected into the molding tool. After closing the molding tool, the foam material composition may expand and cure to form a component, and heat may be applied to cure the resin coatings into skins. For example, an external skin may be formed by the resin coatings on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed by the resin coatings on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

Cast components having surfaces with resin coatings

Methods for detecting irregularities in a composite structure can include obtaining temperature data from a surface of the composite structure while the composite structure undergoes a thermal change. An irregularity in the composite structure is detected based on the temperature data.

Automated thermographic inspection for composite structures

Methods for detecting irregularities in a composite vehicle can include cooling the composite vehicle to a substantially uniform first temperature, heating a surface of the composite vehicle to a second temperature that is higher than the first temperature, and obtaining temperature data from the composite vehicle after the surface has been heated. An irregularity in the composite vehicle is detected based on the temperature data.

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Sammamish, WA, United States of America

Prescott Gee Glynn