Additive manufacturing-enabled platform for modular construction of vehicles using definition nodes

Patent metadata

Field	Value
Publication number	US-2019391563-A1
Application number	US-201916439615-A
Country	US
Kind code	A1
Filing date	Jun 12, 2019
Priority date	Jun 22, 2018
Publication date	Dec 26, 2019
Grant date	—

Abstract

A platform for building a plurality of vehicle types is disclosed. In an embodiment, a facility may include a processing system for designing a plurality of definition nodes for a vehicle and identifying a relative position for each definition node. Based on the design, the internal volume and other vehicle parameters can be determined. The facility includes a 3-D printer for additively manufacturing the definition nodes. In an embodiment, a plurality of commercial-off-the-shelf (COTS) parts are acquired and the definition nodes are designed to interface with the COTS parts. The facility may also include a station, or primary location where the major portions of the vehicle are assembled. In another embodiment, multiple such geographically-distributed facilities can be used, such that one facility can manufacture a desired vehicle type on behalf of another facility, e.g., in the event of an overflow.

First claim

What is claimed is:

1 . A method for manufacturing a vehicle, comprising:
designing a plurality of definition nodes for the vehicle; identifying a relative position for each definition node; additively manufacturing the definition nodes; and assembling the vehicle with the definition nodes in the identified positions.

2 . The method of claim 1 , wherein the positions define a vehicle profile comprising one or more modular systems.

3 . The method of claim 1 , wherein the positions are based at least in part on one or more internal volume requirements of the vehicle.

4 . The method of claim 1 , further comprising, upon identifying the position for each definition node;
designing or acquiring a plurality of panels and vehicle parts; and identifying a position of the panels and vehicle parts relative to the position of each definition node.

5 . The method of claim 1 , further comprising:
designing the vehicle to include a plurality of commercial off-the-shelf (COTS) parts; designing the definition nodes to interface with the COTS parts to produce modular features; and manufacturing the vehicle incorporating the COTS parts and the modular features.

6 . The method of claim 1 , further comprising:
identifying an electric vehicle (EV) propulsion system for use in the vehicle; and identifying the location of each definition node based at least in part on a desired position of elements of the EV propulsion system.

7 . The method of claim 5 , wherein the COTS parts and definition nodes are further used to manufacture a multi-material vehicle.

8 . The method of claim 6 , further comprising:
manufacturing the vehicle to incorporate the EV propulsion system.

9 . The method of claim 1 , further comprising:
manufacturing a plurality of vehicle types, each vehicle type manufactured based in part on
designing a set of definition nodes,
positioning the definition nodes in the set based on one or more internal volume requirements for each vehicle type,
additively manufacturing the set of definition nodes for each vehicle type, and
assembling a desired vehicle based on the position of the definition nodes.

10 . The method of claim 9 , further comprising:
acquiring a plurality of commercial-off-the-shelf (COTS) parts for the desired vehicle; and interfacing one or more of the definition nodes with at least one of the COTS parts.

11 . The method of claim 1 , wherein the vehicle comprises at least one non-definition node.

12 . The method of claim 10 , further comprising:
identifying an electric vehicle (EV) propulsion system for use in the vehicle; and identifying the position of each definition node in the set based at least in part on a desired position of elements of the EV propulsion system.

13 . A facility for manufacturing a plurality of vehicle types, comprising:
(i) a processing system configured to
design a definition node for each section;
identify a relative position for each definition node;
(ii) at least one 3-D printer configured to additively manufacture the definition nodes; and (iii) a station for manufacturing one of the plurality of vehicle types using the definition nodes in the identified positions.

14 . The facility of claim 13 , wherein the processing system is configured to identify a plurality of commercial-off-the-shelf (COTS) parts for interfacing with one or more of the definition nodes.

15 . The facility of claim 14 , wherein the station is configured to manufacture one of the plurality of vehicle types using the COTS parts.

16 . The facility of claim 13 , wherein the processing system is further configured to design an EV propulsion system for use in one of the plurality of vehicle types.

17 . The facility of claim 16 , wherein the station is configured to manufacture the one of the plurality of vehicle types using the EV propulsion system.

18 . A system of geographically distributed facilities for manufacturing a plurality of respective vehicle types, each facility comprising:
(i) a processing system configured to
design a plurality of definition nodes for a vehicle;
identify a relative position for each definition node;
(ii) at least one 3-D printer configured to additively manufacture the definition nodes; and (iii) a station for manufacturing one of the plurality of vehicle types using the definition nodes in the identified location.

19 . The system of claim 18 , wherein:
the processing system is configured to identify a plurality of commercial-off-the-shelf (COTS) parts for interfacing with one or more of the definition nodes; the station is configured to assemble one of the plurality of vehicle types using the COTS parts and the definition nodes; and the assembled one of the vehicle types comprises one or more modular features.

20 . The facilities of claim 18 , wherein one facility is configured to design a desired vehicle on behalf of another facility in the event of an impediment at the another facility.

Assignees

• Divergent Tech Inc

Inventors

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

Classifications

• B62D27/023

  Assembly of structural joints · CPC title

• G05B2219/49023

  3-D printing, layer of powder, add drops of binder in layer, new powder · CPC title

• G05B19/4099 Primary

  Surface or curve machining, making three-dimensional [3D] objects, e.g. desktop manufacturing · CPC title

• B62D29/043

  Superstructures (B62D25/161 takes precedence) · CPC title

• B62D29/041

  Understructures · CPC title