Am cylinder manufacturing method using sacrificial build tube

Patent metadata

Field	Value
Publication number	US-12318839-B2
Application number	US-202318157579-A
Country	US
Kind code	B2
Filing date	Jan 20, 2023
Priority date	Feb 4, 2022
Publication date	Jun 3, 2025
Grant date	Jun 3, 2025

Abstract

An additive manufacturing system and process for manufacturing aircraft parts is disclosed. The process applying an additive manufacturing process to a build tube formed around a longitudinal axial direction of the build tube by rotating the build tube around a longitudinal axis. Then, translating, by the additive manufacturing process, a print-head in a parallel configuration to the longitudinal axis to enable the print-head to deposit an aerospace grade material on a surface of the build tube to form a manufactured component. After completion of the additive manufacturing process, applying another process using a device wherein the device applies a machining process in the longitudinal axial direction to remove the build tube wherein the machining process comprising machining an interior surface of the manufactured component to expose the interior surface of the manufactured component.

First claim

What is claimed is:

1. A method, comprising:
applying an additive manufacturing process to a build tube around a longitudinal axial direction of the build tube by rotating the build tube around a longitudinal axis;
translating, by the additive manufacturing process, a print-head in a parallel configuration to the longitudinal axis to enable the print-head to deposit an aerospace grade material on a surface of the build tube to form a manufactured component; and
after completion of the additive manufacturing process, applying, by a device, a machining process in the longitudinal axis of the manufactured component to incompletely remove the build tube, wherein the machining process comprises machining the build tube in an interior of the manufactured component to expose most but not all of the interior surface of the manufactured component.

2. The method of claim 1 , wherein the manufactured component comprises a manufactured cylinder.

3. The method of claim 1 , wherein the build tube is used as a sacrificial component and removed by the machining process applied to the build tube.

4. The method of claim 1 , wherein the machining process exposes an interior layer of the manufactured component that is composed of the aerospace grade material.

5. The method of claim 1 , further comprising:
configuring the build tube as a sacrificial component to manufacture the manufactured component.

6. The method of claim 5 , wherein the additive manufacturing process is applied by the print-head configured to deposit the aerospace grade material on the surface of the build tube to form the manufactured component.

7. A non-transitory computer readable medium comprising a plurality of instructions which, when executed by a controller, cause the controller to:
rotate a sacrificial component around a longitudinal axis to enable a print-head to deposit aerospace grade material on a surface of the sacrificial component;
deposit, by the print-head, the aerospace grade material on the surface of the sacrificial component;
deposit, by the print-head, a protective coating on the surface of the aerospace grade material; and
in response to a completion of the deposit of the aerospace grade material on the surface of the sacrificial component and the deposit of the protective coating on the surface of the aerospace grade material, apply, by another controller using a device, a machine process in the longitudinal axis of a manufactured component to incompletely remove the sacrificial component and expose most but not all of the interior surface of the manufactured component that comprises the aerospace grade material.

8. The non-transitory computer readable medium according to claim 7 , wherein the instructions, when executed by the another controller, cause the another controller to remove the sacrificial component by a machine process that is applied to an interior of the sacrificial component.

9. The non-transitory computer readable medium according to claim 8 , wherein the instructions, when executed by the another controller, causes the another controller to apply the machine process to an interior layer that comprises the sacrificial component.

10. The non-transitory computer readable medium according to claim 9 , wherein the instructions, when executed by the another controller, cause the controller to expose the interior surface of the manufactured component that is composed mostly of the aerospace grade material.

11. The non-transitory computer readable medium according to claim 10 , wherein the sacrificial component is composed of a material that is different than the aerospace grade material that makes up the manufactured component.

12. The method of claim 1 , further comprising:
translating, by the additive manufacturing process, the print-head in the parallel configuration to the longitudinal axis to enable the print-head to deposit a protective coating layer on a surface of the aerospace grade material.

Assignees

• Goodrich Corp

Inventors

• Allen Jason Bradley

Classifications

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B22F10/30

  Process control · CPC title

• B22F10/66

  by mechanical means · CPC title

• B22F10/25 Primary

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

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title