Structures and methods for high volume production of complex structures using interface nodes

Patent metadata

Field	Value
Publication number	US-11786971-B2
Application number	US-201715809913-A
Country	US
Kind code	B2
Filing date	Nov 10, 2017
Priority date	Nov 10, 2017
Publication date	Oct 17, 2023
Grant date	Oct 17, 2023

Abstract

A high precision Interface Node is disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. The Interface Node may connect with another component or a Linking Node. The Interface Node is manufactured to achieve high precision functionality while enabling volume production. Current additive manufacturing technologies allow for the printing of high precision features to be manufactured, but generally this is performed at a slower rate. Consequently, in one aspect, the size of the Interface Nodes is reduced in order to overcome at least part of the slower production volume caused by creating the high precision Interface Nodes. The components and Linking Nodes to which the Interface Node is connected may only have basic features and functions. Accordingly, this latter category of components may use a high print rate and thus high production volume. In other embodiments, these low precision components may also be produced using a non-print manufacturing technology, such as casting, forging, etc., that may provide the requisite high throughput, or to high precision machined parts that lack the geometric flexibility of the Interface Node. In an embodiment, the Interface Nodes may be connected to other components via a Linking Node.

First claim

What is claimed is:

1. An apparatus, comprising:
a component manufactured using a production process; and
an Interface Node (IN) additively manufactured (AM), the IN manufactured using a production process different from the production process of the component, the IN having:
at least one connection feature at an interface of the IN configured to connect to the component, the component being additively manufactured using a production process different from a print process of the IN; and
at least one structure, different from the at least one connection feature and separated from the interface of the IN, having a reduced size when additively manufactured using the production process of the IN instead of the production process of the component.

2. The apparatus of claim 1 , wherein the component comprises an AM Linking Node.

3. The apparatus of claim 1 , wherein the at least one connection feature is further configured to connect to a Linking Node.

4. The apparatus of claim 1 , wherein the reduced size when additively manufacturing using the production process of the IN instead of the production process of the component provides increased production capacity.

5. The apparatus of claim 1 , further comprising at least one of a set of complex features including a structural feature, a thermal feature, a multi-material feature comprising more than one material or combination thereof, a material characteristic, or a tolerance requirement.

6. The apparatus of claim 1 , wherein the component includes another connection feature configured for engaging the at least one connection feature of the IN.

7. The apparatus of claim 1 , wherein the production process of the component comprises Directed Energy Deposition (DED).

8. The apparatus of claim 7 , wherein the at least one connection feature comprises an engineered surface configured to maximize a surface area for improving a weld joint with a deposited material used for the DED.

9. The apparatus of claim 1 , wherein the at least one connection feature is coupled to the component via a Linking Node.

10. The apparatus of claim 1 , wherein the IN comprises a different material than the component.

11. An apparatus comprising:
a cast component; and
an Interface Node (IN) additively manufactured (AM), the IN having:
at least one connection feature configured to connect to the cast component; and
at least one feature from a set including a geometrically complex feature, a thermally complex feature, a multi-material complex feature comprising different materials or compositions thereof, or a complex tolerance requirement,
wherein the at least one feature is adapted to replace at least one complex feature associated with the cast component without substantially reducing throughput of the cast component.

12. The apparatus of claim 11 , wherein the at least one connection feature is further configured to connect to a cast or forged Linking Node.

13. The apparatus of claim 11 , wherein the at least one connection feature comprises a male connection feature for engaging with a female connection feature on the cast component.

14. The apparatus of claim 13 , wherein the male connection feature comprises a tongue for a tongue-and-groove connection.

15. The apparatus of claim 11 , wherein the at least one connection feature comprises a female connection feature for engaging with a male connection feature on the cast component.

16. The apparatus of claim 15 , wherein the female connection feature comprises a groove for a tongue-and-groove connection.

17. The apparatus of claim 11 , wherein the at least one connection feature further comprises a sealant groove.

18. The apparatus of claim 11 , wherein the at least one connection feature comprises at least one fluid port configured for use as an adhesive injection port or a vacuum port.

19. An apparatus, comprising:
a cast component; and
an Interface Node (IN) additively manufactured (AM), the IN having:
at least one connection feature configured to connect to the cast component;
an adhesive inlet channel; and

an isolation feature coupled to the IN and arranged between an interface of the IN and the cast component.

20. The apparatus of claim 19 , further comprising a vacuum channel.

21. The apparatus of claim 19 , wherein the IN and the cast component comprise different metals.

22. The apparatus of claim 21 , wherein the at least one connection feature is further configured to connect to an extrusion or a panel.

23. The apparatus of claim 19 , wherein the at least one connection feature is further configured to connect to a connecting tube.

24. The apparatus of claim 23 , wherein the at least one connection feature further comprises a sealant groove.

25. An apparatus comprising:
a machined component; and
an Interface Node (IN) additively manufactured (AM), the IN having:
at least one connection feature configured to connect to the machined component, the machined component produced using a production process with lower geometric flexibility than a print process of the IN; and
at least one feature from a set including a geometrically complex feature, a thermally complex feature, a multi-material complex feature comprising different materials or compositions thereof, or a complex tolerance requirement,
wherein the at least one feature is adapted to replace at least one complex feature associated with the machined component without substantially reducing throughput of the machined component.

26. The apparatus of claim 25 , wherein the at least one connection feature is further configured to connect to a forged component.

27. The apparatus of claim 25 , wherein the at least one connection feature is further configured to connect to a Linking Node.

28. The apparatus of claim 25 , wherein the at least one connection feature comprises a male connection feature for engaging with a female connection feature on the machined component.

29. The apparatus of claim 25 , wherein the at least one connection feature comprises a female connection feature for engaging with a male connection feature on the machined component.

30. The apparatus of claim 29 , wherein the female connection feature comprises a groove for a tongue-and-groove connection.

31. The apparatus of claim 30 , wherein the male connection feature comprises a tongue for a tongue-and-groove connection.

32. The apparatus of claim 25 , wherein the at least one connection feature comprises at least one fluid port configured for use as an adhesive inlet port or a vacuum port.

33. An apparatus comprising:
a machined component; and
an Interface Node (IN) additively manufactured (AM), the IN having:
at least one connection feature configured to connect to the machined component, the machined component produced using a production process with lower geometric flexibility than a print process of the IN;
an adhesive inlet channel; and

an isolation feature coupled to the IN and arranged between an interface of the IN and the machined component.

34. The apparatus of claim 33 , further comprising an isolation feature between the IN and the machined component.

35. The apparatus of claim 34 , wherein the IN and the machined component comprise different metals.

3

Assignees

• Divergent Tech Inc

Inventors

• Czinger Kevin Robert
• Tenhouten Broc William
• Martinez Antonio Bernerd
• Massey Jr Steven Blair
• Lakshman Narender Shankar
• Kreig William David
• Gunner Jon Paul
• Tenhouten David Brian
• El Naga Eahab Nagi
• Zafar Muhammad Faizan

Classifications

• B22F7/08 Primary

  with one or more parts not made from powder {(B22F7/062 takes precedence)} · CPC title

• B22F3/105

  by using electric current {other than for infrared radiant energy}, laser radiation or plasma (B22F3/11 takes precedence){; by ultrasonic bonding (B22F3/115 takes precedence)} · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title