Methods and apparatus for additively manufactured endoskeleton-based transport structures

Patent metadata

Field	Value
Publication number	US-11897163-B2
Application number	US-202117171867-A
Country	US
Kind code	B2
Filing date	Feb 9, 2021
Priority date	Jul 25, 2017
Publication date	Feb 13, 2024
Grant date	Feb 13, 2024

Abstract

Some embodiments of the present disclosure relate to an additively manufactured transport structure. The transport structure includes cavities into which components that use an external interface are inserted. A plurality of components are assembled and integrated into the vehicle. In an embodiment, the components and frame are modular, enabling reparability and replacement of single parts in the event of isolated failures.

First claim

What is claimed is:

1. A transport structure, comprising:
a 3-D printed frame comprising a structure configured to accept loads and to protect an occupant in an impact event;
a plurality of components assembled onto the 3-D printed frame; and
a separate body assembled over an exterior surface of the 3-D printed frame.

2. The transport structure of claim 1 , further comprising a suspension system coupled to the 3-D printed frame.

3. The transport structure of claim 2 , wherein at least a portion of the suspension system is 3-D printed.

4. The transport structure of claim 2 , wherein the suspension system includes at least a front suspension system or a rear suspension system.

5. The transport structure of claim 1 , further comprising a dashboard structure coupled to the 3-D printed frame, wherein at least a portion of the dashboard structure is 3-D printed, or the dashboard structure is co-printed with the 3-D printed frame.

6. The transport structure of claim 1 , wherein the loads include at least structural loads or road loads.

7. The transport structure of claim 1 , wherein the body is a 3-D printed body.

8. The transport structure of claim 1 , wherein the 3-D printed frame is 3-D printed in modules or in a single rendering.

9. The transport structure of claim 1 , further comprising a safety feature, wherein the safety feature is 3-D printed.

10. The transport structure of claim 9 , wherein the safety feature includes a nosecone.

11. The transport structure of claim 9 , wherein the safety feature includes a safety cell.

12. The transport structure of claim 9 , wherein the safety feature includes a crumple zone.

13. The transport structure of claim 1 , wherein the frame comprises 3-D printed metal.

14. A method for producing a transport structure, comprising:
3-D printing a frame, the 3-D printed frame comprising a structure configured to accept loads and to protect an occupant in an impact event;
assembling a separate body over an exterior surface of the 3-D printed frame; and
assembling a plurality of components onto the 3-D printed frame.

15. The method of claim 14 , further comprising 3-D printing the body.

16. The method of claim 14 , further comprising 3-D printing the frame in modules or in a single rendering.

17. The method of claim 14 , further comprising 3-D printing a safety feature of the transport structure.

18. The method of claim 17 , wherein the safety feature includes a nosecone.

19. The method of claim 17 , wherein the safety feature includes a safety cell.

20. The method of claim 17 , wherein the safety feature includes a crumple zone.

21. The method of claim 14 , further comprising coupling a suspension system to the 3-D printed frame.

22. The method of claim 21 , further comprising 3-D printing at least a portion of the suspension system.

23. The method of claim 21 , wherein the suspension system includes at least a front suspension system or a rear suspension system.

24. The method of claim 14 , wherein the frame comprises 3-D printed metal.

25. The method of claim 14 , further comprising 3-D printing at least a portion of a dashboard structure for assembly within the frame.

26. The method of claim 14 , wherein the loads include at least structural loads or road loads.

Assignees

• Divergent Tech Inc

Inventors

• Czinger Kevin Robert
• Tenhouten Broc William
• Macey Stuart Paul
• O'Connell David Charles
• Gunner Jon Paul
• Martinez Antonio Bernerd
• Lakshman Narender Shankar

Classifications

• Y02P10/25

  Process efficiency · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B62D65/00

  Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for · 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