Methods and apparatus for additively manufactured endoskeleton-based transport structures

Patent metadata

Field	Value
Publication number	US-12377576-B2
Application number	US-202418404799-A
Country	US
Kind code	B2
Filing date	Jan 4, 2024
Priority date	Jul 25, 2017
Publication date	Aug 5, 2025
Grant date	Aug 5, 2025

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;
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 , wherein one component of the plurality of components is co-printed with the 3-D printed frame.

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

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

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

6. The transport structure of claim 1 , wherein the 3-D printed frame is 3-D printed in modules.

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

8. 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.

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

10. The transport structure of claim 9 , wherein the suspension system includes at least a front suspension system or a rear suspension system.

11. The transport structure of claim 9 , wherein at least a portion of the suspension system is 3-D printed.

12. The transport structure of claim 11 , wherein the at least a portion includes at least a control arm, or a hinge, or a housing.

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

14. The transport structure of claim 13 , wherein the safety feature includes a nosecone.

15. The transport structure of claim 13 , wherein the safety feature includes a safety cell.

16. The transport structure of claim 13 , wherein the safety feature includes a crumple zone.

17. 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;
assembling a plurality of components onto the 3-D printed frame; and
assembling a separate body over an exterior surface of the 3-D printed frame.

18. The method of claim 17 , wherein one component of the plurality of components is co-printed with the 3-D printed frame.

19. The method of claim 17 , wherein the 3-D printed frame includes 3-D printed metal.

20. The method of claim 17 , wherein the loads include at least structural loads or road loads.

21. The method of claim 17 , further comprising 3-D printing the body.

22. The method of claim 17 , further comprising 3-D printing the frame in modules.

23. The method of claim 17 , further comprising 3-D printing the frame in a single rendering.

24. The method of claim 17 , further comprising coupling a dashboard structure to the 3-D printed frame.

25. The method of claim 24 , further comprising 3-D printing at least a portion of the dashboard structure.

26. The method of claim 17 , further comprising coupling a suspension system to the 3-D printed frame.

27. The method of claim 26 , wherein the suspension system includes at least a front suspension system or a rear suspension system.

28. The method of claim 26 , further comprising 3-D printing at least a portion of the suspension system.

29. The method of claim 28 , wherein the at least a portion includes a control arm, or a hinge, or a housing.

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

31. The method of claim 30 , wherein the safety feature includes a nosecone.

32. The method of claim 30 , wherein the safety feature includes a safety cell.

33. The method of claim 30 , wherein the safety feature includes a crumple zone.

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

• B62D65/02

  Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components · CPC title

• B62D27/023

  Assembly of structural joints · CPC title

• B22F3/115

  by spraying molten metal, i.e. spray sintering, spray casting · CPC title

• B22F3/002

  Manufacture of articles essentially made from metallic fibres · CPC title