Hrl Laboratories, LLC

Gm Global Technolgoy Operations, Inc.

The Boeing Company

Other

University of Ca

William B Carter

Alan Jon Jacobsen

Tobias A Schaedler

Christopher Stephen Roper

Jacob Michael Hundley

Sophia Shu Yang

Peter David Brewer

Jeffrey Allan Rock

Gerald W Fly

Yeh-Hung Lai

Zak C Eckel

Keith E Newman

Geoffrey P McKnight

Adam Franklin Gross

Ping Liu

Robert E Doty

Adam E Sorensen

Andrew Paul Nowak

Robert W Cumberland

Kevin J Maloney

Nancy L Johnson

Alan L Browne

Joanna A Kolodziejska

Christopher Paul Henry

John Hunter Martin

Guillermo A Herrera

Brennan D Yahata

Jason A Graetz

Chia-Ming Chang

Keith V Guinn

Jie Jiang

Patrick B Usoro

Nilesh D Mankame

Xiujie Gao

Hung P Nguyen

John S Wang

Tao Xie

Andrew C Keefe

Oleg M Efimov

Jeffrey L Rogers

Eric C Clough

Chaoyin Zhou

Cameron G Massey

David Kisailus

Adour Vahe Kabakian

Steven G Corrion

Randall Jay Moss

James Y Khoury

Jeff D Williams

Stephen Edward Lehman

Yu Qiao

David Page

Lawrence C Maugh

Jie Ensberg

Chia-Ming “Gavin” Chang

Artie J Martin

Sha-Chelle Manning

Jenny Jiang

Disclosed herein are surface-functionalized powders which alter the solidification of the melted powders. Some variations provide a powdered material comprising a plurality of particles fabricated from a first material, wherein each of the particles has a particle surface area that is continuously or intermittently surface-functionalized with nanoparticles and/or microparticles selected to control solidification of the powdered material from a liquid state to a solid state. Other variations provide a method of controlling solidification of a powdered material, comprising melting at least a portion of the powdered material to a liquid state, and semi-passively controlling solidification of the powdered material from the liquid state to a solid state. Several techniques for semi-passive control are described in detail. The methods may further include creating a structure through one or more techniques selected from additive manufacturing, injection molding, pressing and sintering, capacitive discharge sintering, or spark plasma sintering.

Semi-passive control of solidification in powdered materials

A method of manufacturing a sandwich structure having an open cellular core and a fluid-tight seal surrounding the core includes coupling a mold to a first facesheet to define a reservoir. The method also includes irradiating a volume of photo-monomer in the reservoir with a series of vertical collimated light beams to form a cured, solid polymer border extending around a periphery of the first facesheet. The method also includes irradiating a remaining volume of photo-monomer in the reservoir with a series of collimated light beams to form an ordered three-dimensional polymer microstructure core defined by a plurality of interconnected polymer optical waveguides coupled to the first facesheet and surrounded by the cured, solid polymer border. The method further includes coupling a second facesheet to the ordered three-dimensional microstructure core and the cured, solid polymer border to form the sandwich structure.

Open cellular sandwich structures having sealed edges and methods of manufacturing the same

An ordered, 3-dimensional, micro-scale, open-cellular truss structure including interconnected hollow polymer tubes. The hollow micro-truss structure separates two fluid volumes which can be independently pressurized or depressurized to control flow, or materials properties, or both. Applications for this invention include deployable structures, inflatable structures, flow control, and vented padding.

Hollow polymer micro-truss structures containing pressurized fluids

A cellular material includes a continuous solid phase including an ordered ceramic material, the solid phase having a solid core including the ordered ceramic material. A composition for forming a cellular material includes: a first UV curable pre-ceramic monomer; a second UV curable pre-ceramic monomer; and a photoinitiator. A method of forming at least one ceramic waveguide includes: securing a volume of a composition including a UV curable pre-ceramic monomer; exposing the composition to a light source to form at least one polymer waveguide including a pre-ceramic material; and converting the pre-ceramic material of the polymer waveguide to a ceramic material to form a ceramic waveguide.

Cellular ceramic materials

Methods of manufacturing a structure having at least one plated region and at least one unplated region. The method includes plating a metal on a polymer structure having a first region accepting the metal and a second region unreceptive to the metal plating. The first region may include fully-cured polymer optical waveguides and the second region may include partially-cured polymer optical waveguides. The first region may include a first polymer composition and the second region may include a second polymer composition different than the first polymer composition.

Structures having selectively metallized regions and methods of manufacturing the same

Architected materials with superior energy absorption properties when loaded in compression. In several embodiments such materials are formed from micro-truss structures composed of interpenetrating tubes in a volume between a first surface and a second surface. The stress-strain response of these structures, for compressive loads applied to the two surfaces, is tailored by arranging for some but not all of the tubes to extend to both surfaces, adjusting the number of layers of repeated unit cells in the structure, arranging for the nodes to be offset from alignment along lines normal to the surfaces, or including multiple interlocking micro-truss structures.

Energy absorbing truss structures for mitigation of injuries from blasts and impacts

A system for forming a micro-truss structure including a reservoir having walls and a flat bottom configured to hold a volume of a liquid photomonomer configured to form a photopolymer when exposed to light, a partially transparent mask secured to, or being, the bottom of the reservoir, a release layer on the mask configured to resist adhesion by the photopolymer, and a blocker positioned a first distance below the mask. The system also includes a light source positioned below the blocker configured to produce collimated light suitable for causing conversion of the photomonomer into the photopolymer, and to which the blocker is opaque, and a first mirror, oblique to the blocker, configured to reflect the light from the light source around the blocker and through the mask and into the reservoir. The blocker is positioned to block a straight path of light from the light source to the mask.

Bottom up apparatus design for formation of self-propagating photopolymer waveguides

A multi-chemistry structure includes: a plurality of interconnected polymer struts arranged in a lattice; a first layer of the lattice including a first array of first unit cells; a second layer of the lattice including a second array of second unit cells; at least one region of the lattice being formed of a first polymer; and at least one region of the lattice being formed of a second polymer different from the first polymer.

Multi-chemistry microlattice structures and methods of manufacturing the same

A sparse micro-truss structure having a series of unit cells arranged in an array is disclosed. Each of the unit cells includes a series of struts interconnected at a node. Adjacent unit cells are spaced apart by a gap. Spacing apart the adjacent unit cells is configured to reduce the sensitivity of the sparse micro-truss structure to premature mechanical failure due to buckling in one or more of the struts compared to related art micro-truss structures having a series of fully interconnected unit cells.

Sparse truss structures and methods of making the same

Described is a micro-lattice damping material and a method for repeatable energy absorption. The micro-lattice damping material is a cellular material formed of a three-dimensional interconnected network of hollow tubes. This material is operable to provide high damping, specifically acoustic, vibration or shock damping, by utilizing the energy absorption mechanism of hollow tube buckling, which is rendered repeatable by the micro-lattice architecture.

Microlattice damping material and method for repeatable energy absorption

A system for fabricating micro-truss structures. A reservoir holds a volume of a liquid photomonomer configured to polymerize to form a photopolymer when exposed to suitable light such as ultraviolet light. A mask at the bottom of the reservoir includes a plurality of apertures. Light enters the reservoir through each aperture from several directions, forming a plurality of self-guided photopolymer waveguides within the reservoir. The light is supplied by one or more sources of collimated light. A plurality of mirrors may reflect the light from a single source of collimated light to form a plurality of collimated beams, that illuminate the photomonomer in the reservoir, through the mask, from a corresponding plurality of directions, to form a micro-truss structure including a plurality of self-guided waveguide members.

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Ventura, CA, United States of America

William B Carter