Northrop Grumman Systems Corporation

Steven J Floyd

Eric G Barnes

Pedro A Gonzalez

Todd Lewis Szallay

Sung S Park

Brett G Morham

Cody J Brown

Reese R Allen

Ryan L Bischoff

Vernon M Benson

Talbot P Thrasher

Timothy R Stone

Chesley Lane

Pedro A Gonzales

A tube element including a first set of spaced apart tape strips helically wound in one direction, and a second set of spaced apart tape strips helically wound in an opposite direction as the first set of tape strips so that the tape strips in the first set periodically cross the tape strips in the second set, where the first and second sets of tape strips define a tube. A set of spaced apart straight tape strips are provided along the length of the tube. An end fitting is secured to an end of the first and second sets of tape strips at one end of the tube, and another end fitting is secured to an end of the first and second sets of tape strips at an opposite end of the tube, where the fittings are configured to be coupled to an end fitting of another tube element.

Tubular support element

A machine for manufacturing tube elements comprised of tape strips. The machine includes a shaft, a disk mounted to one end of the shaft, a motor coupled to an opposite end of the shaft, and a plate mounted to the shaft. The plate includes a plurality of spools mounted to the plate, where a separate one of the strips is wound on each spool. In one embodiment, the machine further includes a rail positioned adjacent to the disk, a slide slidably secured to the rail and including an end support configured to hold ends of the tape strips, and an indexer configured to pull the slide on the rail away from the disk. The tape strips are unwound from the spools when the indexer pulls the slide in a manner so that the tape strips ride in a spaced apart manner around the disk to form the tube element.

Structural tube element fabricator

A system for fabricating a composite part using a 3D printing machine. The system includes means for forming the part by depositing consecutive part layers each including rows of filaments made of a part material from the machine, where depositing each part layer includes non-sequentially depositing one set of a plurality of filaments so that a gap is formed between the filaments and then depositing any number of additional sets of filaments so that each adjacent pair of filaments in each additional set of filaments are non-sequentially deposited.

System for deposition and fabrication of 3D integrated composite structures

A method for fabricating a composite part using a 3D printing machine. The method includes forming a support structure by depositing consecutive support structure layers including rows of filaments made of a support structure material from the machine on a build plate, smoothing out a top surface of the support structure after it is formed, and forming the part by depositing consecutive part layers including rows of filaments made of a part material from the machine on the support structure.

Method for fabricating a 3D composite structure including smoothing of support structures

A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing consecutive part layers each including rows of filaments made of a part material from the machine, where depositing each part layer includes non-sequentially depositing one set of a plurality of filaments so that a gap is formed between the filaments and then depositing any number of additional sets of filaments so that each adjacent pair of filaments in each additional set of filaments are non-sequentially deposited.

Methods for deposition and fabrication of 3D integrated composite structures

A method for fabricating a composite part using a 3D printing machine. The method includes forming the part by depositing an alternating sequence of first part layers including rows of filaments made of a first part material and depositing second part layers including rows of filaments made of a second part material, where the second part material is different than the first part material and provides adhesion between the first part layers.

Method for fabricating multi-material structure for 3D integrated composite structures

A 3D printing machine for fabricating high performance 3D integrated composite structures, where the machine includes a robot having a base portion, a robot arm and a rotatable connector secured to the arm opposite to the base portion, at least one source of an extrudable material, and an end-effector mounted to the rotatable connector and including at least one extruder module for extruding the extrudable material. The extruder module includes a nozzle assembly for extruding heated material out of the end-effector, and the end-effector is rotatable relative to the structure by the rotatable connector so that the nozzle assembly can be oriented normal to the part in different orientations without significantly changing a pose of the robot.

Methods and apparatus for fabrication of 3D integrated composite structures

A printing machine for fabricating high performance 3D integrated composite structures. The machine includes a robot having a base portion, a robot arm and an end joint secured to the arm opposite to the base portion, at least one source of an extrudable material, and an end-effector mounted to the end joint. The end-effector includes at least one extruder module for extruding the extrudable material and a rotary assembly, where the extruder module includes a nozzle assembly for extruding heated material out of the end-effector. The extruder module is mounted to the rotary assembly and the rotary assembly is rotatable so as to rotate the nozzle assembly relative to the part without rotating the end-effector.

Printing machine for fabricating 3D integrated composite structures and having a rotatable extruder module

A printing machine for fabricating high performance 3D integrated composite structures, where the machine includes a robot having a base portion, a robot arm and an end joint secured to the arm opposite to the base portion, a plurality of sources of extrudable material, and an end-effector mounted to the end joint. The end-effector includes a multiple-extruder module having a first extruder and a second extruder each including a separate nozzle assembly, wherein the first extruder receives one extrudable material and the second extruder receives another extrudable material.

Growing community of inventors

Monterey Park, CA, United States of America

Steven J Floyd