The Boeing Company

Trevor E Tucker

Brett Ian Lyons

Aaron William Bartel

Daniel Joseph Braley

Eric Eldon Deck

Andrew Lawrence Bauer

Nicole Renee Williams

Thomas Joseph Gonze

Garrett B Peters

Janet Mary Wick

Nicole R Williams

Janet M Wick

Thomas J Gonze

Core structures () for composite panels () of an aircraft (), composite panels () and aircraft () including the core structures (), and methods () of manufacturing the composite panels () are disclosed herein. The core structures () include a first side (), a second side (), and a connecting region () that interconnects an upper portion () of the first side () with an upper portion () of the second side (). The first side (), the second side (), and the connecting region () at least partially define an antenna housing (), which defines a housing volume () configured to contain an aircraft antenna () of the aircraft (), and an electromagnetic wave transmission region () configured to permit electromagnetic waves to pass therethrough. The electromagnetic wave transmission region () defines a plurality of kite-shaped voids () arranged in a repeating pattern and bounded by a corresponding plurality of walls (), at least 10% of which extends at least substantially perpendicular to a surface () that bounds the electromagnetic wave transmission region ().

Core structures for composite panels of an aircraft, composite panels and aircraft including the core structures, and methods of manufacturing the composite panels

A method of forming a monolithic aircraft part includes additively forming a first cavity, defined by a first wall of the part, additively forming a second cavity, defined by a second wall of the part, so that the first cavity and the second cavity are not in communication with each other and share a common wall portion so that the second cavity is partially contained within the first cavity. Additively forming the first cavity includes forming a first aperture, extending through the first wall, forming a second aperture, extending through the first wall, and forming a first inner surface of the first wall, defining a first shape, wherein a first object, permanently having the first shape, would not be able to be mechanically extracted from the first cavity via the first aperture or the second aperture.

Method of making a monolithic part

One example of the present disclosure relates to a monolithic part including an exterior wall and a first cavity. The first cavity includes a first aperture in communication with the exterior wall and a first inner surface defining a first shape. The first shape prevents extraction from the first cavity, via the first aperture, of a first virtual object having the first shape.

Monolithic part and method of forming the monolithic part

Growing community of inventors

Seattle, WA, United States of America

Trevor E Tucker