Additive manufacturing aerospace panel and method

Abstract

The invention relates to an additive manufactured aerospace panel and a method. The aerospace panel includes a first skin, a second skin spaced apart from the first skin, and a first truss structure connecting the first skin to the second skin. The first truss structure includes a plurality of truss members. Each truss member is integral with the first skin and the second skin such that the first skin, the second skin, and the first truss structure collectively form a single integral jointless structure. At least one of the skins further includes at least one grillage region including a grillage grid and an array of openings.

Description

Technical Field

[0001] The present disclosure relates generally to aerospace structures and, more particularly, to additively manufactured aerospace panels and methods for additively manufacturing aerospace panels. Background Art

[0002] Aeronautics and aerospace provide a particularly harsh environment for vehicles. Space is a very harsh environment for spacecraft such as satellites. In addition to the danger of harmful radiation and foreign object damage (e.g., from orbital debris impact), thermal management is particularly challenging in space or high-speed applications. Many aerospace vehicles are made of composite materials, such as strong and lightweight sandwich panels. However, such panels typically include a core material bonded between two thin skins, which results in high thermal impedance. The manufacture of composite sandwich panels is also expensive and labor-intensive. The packaging and removal of tools, the precise arrangement of each layer, and the multiple stages of curing and stacking all require a lot of time and hard work. For localized features, such as shielding and reinforcement, separate components are attached after production, thereby requiring further expenses and labor.

[0003] Additive manufacturing (AM) is rapidly gaining popularity in many industries as a method of rapid production at a relatively low cost. AM, sometimes referred to as 3D printing, can be used to create a physical object from a 3D model by incrementally building the object. AM typically applies raw materials, which are then selectively joined or fused to produce the desired object. The raw materials are typically applied in layers, where the thickness of each layer may depend on the specific technology used.

[0004] Typically, the raw material is in granular or powder form, applied as a layer, and then selectively melted by a heat source. In many cases, the upper surface of a bed of such material is melted, and the growing workpiece then drops slightly into the bed itself. A new layer of raw material is then applied to the bed, and the next layer is fused to the previous layer. Granular raw materials may include, for example, thermoplastic polymers, thermosetting polymers, metal powders, metal alloy powders, or ceramic powders, which may be melted using a computer-controlled heat source such as a scanning laser or a scanning electron beam. Exemplary methods include selective laser melting (SLM), direct metal laser sintering (DMLS), selective laser sintering (SLS), fused deposition modeling (FDM), and electron beam melting (EBM), among others.

[0005] Conventional part designs for subtractive manufacturing or composite laminate construction may be inefficient or even inoperable with AM. Depending on the process and materials used, unsupported features may collapse, fine features may exhibit insufficient definition, and / or warping and cracking may occur. New designs are needed that maintain the functionality of traditional parts while being able to effectively use AM methods. Summary of the invention

[0006] Examples of aerospace panels, aerospace vehicles, and examples of systems, apparatuses, and methods involving additively manufactured aerospace panels are disclosed. The following is a non-exhaustive list of examples of subject matter according to the present disclosure that may or may not be claimed.

[0007] In one or more examples, the disclosed aerospace panel includes: a first skin; a second skin spaced apart from the first skin; and a first truss structure connecting the first skin to the second skin. The first truss structure includes a plurality of truss members. Each truss member is integral with the first skin and the second skin, such that the first skin, the second skin, and the first truss structure together form a single, unitary, jointless structure. At least one of the first skin and the second skin includes at least one grid region, the at least one grid region defining a grid configured to eliminate auxiliary printing supports. The at least one grid region includes a grid grid and an array formed by openings.

[0008] In one or more examples of the disclosed aerospace panel, the first skin has a first grid formed by stiffeners, the second skin has a second grid formed by stiffeners, and each truss member extends between a first node defined at an intersection of the first grid formed by stiffeners and a second node defined at an intersection of the second grid formed by stiffeners. In the at least one grid region, the grid grid includes one or more grids formed by grid stiffeners.

[0009] In one or more examples of the disclosed aerospace panel, the first grid formed by the reinforcement defines one or more first grid squares. The second grid formed by the reinforcement defines one or more second grid squares. The first grid squares are offset from the second grid squares such that each first node is aligned with a geometric center of one of the second grid squares when the aerospace panel is viewed along a direction orthogonal to the first skin. The one or more grids formed by the lattice reinforcement define one or more lattice grid squares corresponding to the one or more first grid squares or the one or more second grid squares of the skin in which the grid formed by the lattice reinforcement is located.

[0010] In one or more examples of the disclosed aerospace panels, at least one of the first grid formed by the skin reinforcement and the second grid formed by the skin reinforcement is non-planar.

[0011] In one or more examples, the disclosed aerospace panel includes a perimeter wall extending between the first skin and the second skin along at least one edge of the aerospace panel. The first skin, the second skin, the first truss structure, and the perimeter wall together form the single integral jointless structure.

[0012] In one or more examples of the disclosed aerospace panel, the plurality of truss members include a plurality of X-shaped truss members. Each X-shaped truss member extends between a pair of first nodes on the first skin and a pair of second nodes on the second skin.

[0013] In one or more examples of the disclosed aerospace panel, the plurality of truss members form an array formed by a core structure having a density that varies across at least one region of the aerospace panel.

[0014] In one or more examples, the disclosed aerospace panel includes: a third skin spaced apart from the second skin; and a second truss structure connecting the second skin to the third skin. The first skin, the second skin, the third skin, the first truss structure, and the second truss structure together form the single integral jointless structure.

[0015] In one or more examples, the disclosed aerospace panel has a major axis parallel to the longitudinal direction of the first skin and the second skin, and a minor axis perpendicular to the major axis and orthogonal to the first skin and the second skin. When the aerospace panel is viewed along a direction perpendicular to both the major axis and the minor axis, each truss member is oriented at a first truss angle of approximately 35 to 50 degrees relative to the minor axis. When the aerospace panel is viewed along the major axis, each truss member is oriented at a second truss angle of approximately 35 to 50 degrees relative to the minor axis.

[0016] In one or more examples of the disclosed aerospace panel, at least one of the first skin and the second skin has an internal channel embedded in the first skin and / or the second skin, respectively.

[0017] In one or more examples, a disclosed aerospace vehicle includes a body having one or more aerospace panels. Each aerospace panel includes: a first skin; a second skin spaced apart from the first skin; and a first truss structure connecting the first skin to the second skin. The first truss structure includes a plurality of truss members. Each truss member is integral with the first skin and the second skin, such that the first skin, the second skin, and the first truss structure together form a single, unitary, jointless structure. At least one of the first skin and the second skin includes at least one grid region, the at least one grid region defining a grid configured to eliminate auxiliary printing supports. The at least one grid region includes a grid formed by grid reinforcements and an array formed by openings.

[0018] In one or more examples, a disclosed method for manufacturing an aerospace panel includes the steps of printing a first skin and a second skin spaced apart from the first skin, while simultaneously printing a plurality of truss members of a first truss structure connecting the first skin to the second skin, thereby forming a single integral jointless structure. At least one of the first skin and the second skin includes at least one grid region, the at least one grid region defining a grid configured to eliminate auxiliary printing supports. The at least one grid region includes a grid grid and an array formed by openings.

[0019] In one or more examples of the disclosed method, the steps of printing the first skin and printing the second skin respectively include the steps of printing a first grid formed by the reinforcement members together with the first skin and printing a second grid formed by the reinforcement members together with the second skin. The step of printing the plurality of truss members includes the steps of printing each truss member to extend between a first node and a second node, the first node being defined at an intersection of the first grid formed by the reinforcement members and the second node being defined at an intersection of the second grid formed by the reinforcement members.

[0020] In one or more examples of the disclosed method, the step of printing the first grid formed by the reinforcement and the step of printing the second grid formed by the reinforcement respectively include the steps of printing the first grid formed by the reinforcement to form one or more first grid squares and printing the second grid formed by the reinforcement to form one or more second grid squares. The first grid squares are offset from the second grid squares so that when the aerospace panel is viewed in a direction perpendicular to the first skin, each first node is aligned with a geometric center of one of the second grid squares. The one or more grids formed by the lattice reinforcement form one or more lattice grid squares, and the one or more lattice grid squares correspond to the one or more first grid squares or the one or more second grid squares of the skin where the grid formed by the lattice reinforcement is located.

[0021] In one or more examples, the disclosed method includes the step of printing a perimeter wall simultaneously with printing the first skin, the second skin, and the first truss structure, the perimeter wall extending between the first skin and the second skin along at least one edge of the aerospace panel.

[0022] In one or more examples of the disclosed method, the step of printing the plurality of truss members includes the step of printing a plurality of X-shaped truss members. Each X-shaped truss member extends between a pair of first nodes on the first skin and a pair of second nodes on the second skin.

[0023] In one or more examples of the disclosed method, the step of printing the plurality of truss members includes the step of printing the plurality of truss members as an array formed of a core structure having a density that varies across at least one region of the aerospace panel.

[0024] In one or more examples, the disclosed method includes: while printing the first skin, the second skin, and the first truss structure, printing a third skin spaced apart from the second skin and printing a second truss structure connecting the second skin to the third skin.

[0025] In one or more examples of the disclosed method, the aerospace panel has a major axis parallel to a longitudinal direction of the first skin and the second skin, and a minor axis perpendicular to the major axis and orthogonal to the first skin and the second skin. The step of printing the plurality of truss members includes the steps of printing each truss member at a first truss angle of about 35 to 50 degrees relative to the minor axis when the aerospace panel is viewed along a direction perpendicular to both the major axis and the minor axis and at a second truss angle of about 35 to 50 degrees relative to the minor axis when the aerospace panel is viewed along the major axis.

[0026] In one or more examples of the disclosed method, the step of printing the first skin and the second skin includes the step of printing at least one of the first skin and the second skin such that an internal channel is embedded in the first skin and / or the second skin.

[0027] In one or more examples of the disclosed method, the step of printing the first skin, the second skin, and the first truss structure includes the following steps: printing the aerospace panel using an additive manufacturing device so that the longitudinal direction of the first skin and the second skin is parallel to the building direction of the additive manufacturing device.

[0028] The features, functions, and advantages can be achieved independently in multiple examples of the present disclosure, or can be combined in other examples, further details of which can be seen with reference to the following description and drawings. Other examples of aerospace panels, aerospace vehicles, and methods disclosed herein will become apparent from the following detailed description, drawings, and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1A is a schematic diagram of an example of an aerospace vehicle;

[0030] Figure 1B is a schematic diagram of an example of a portion of an additively manufactured aerospace panel for an aerospace vehicle;

[0031] Figure 1C is a schematic diagram of an example of a portion of an additively manufactured aerospace panel for an aerospace vehicle;

[0032] Figure 1D is a schematic diagram of an example of a portion of an additively manufactured aerospace panel for an aerospace vehicle;

[0033] Figure 2 is a schematic isometric view of an example of an additively manufactured panel;

[0034] Figure 3is a schematic isometric view of an example of an additively manufactured panel;

[0035] Figure 4 is a schematic isometric view of an example of an additively manufactured panel;

[0036] Figure 5 is a schematic isometric view of an example of an additively manufactured panel;

[0037] Figure 6 is a schematic isometric view of an example of an additively manufactured panel;

[0038] Figure 7 is a schematic elevational cross-sectional view of an example of a portion of an additively manufactured panel;

[0039] Figure 8 is a schematic isometric view of an example of a core structure of an additively manufactured panel;

[0040] Fig. 9 is a schematic isometric view of an example of a core structure of an additively manufactured panel;

[0041] Fig.10 It was taken along line 10-10 Figure 6 A schematic cross-sectional view of an example of an additively manufactured panel;

[0042] Fig.11 is a schematic elevational cross-sectional view of an example of a portion of an additively manufactured panel;

[0043] Fig.12 is a schematic isometric view of an example of a core structure of an additively manufactured panel;

[0044] Fig.13 is a schematic isometric view of an example of a core structure of an additively manufactured panel;

[0045] Fig.14 is a schematic elevational cross-sectional view of an example of an additively manufactured panel;

[0046] Fig.15 is a schematic elevation view of an example of an additively manufactured panel having a varying core density;

[0047] Fig.16 is a schematic elevation view of an example of an additively manufactured panel with a locally thickened skin;

[0048] Fig.17 is a schematic elevation view of an example of an additively manufactured panel having an enclosure structure;

[0049] Fig.18 Observed from an orthogonal direction Fig.17 A schematic front view of an example of an additively manufactured panel;

[0050] Fig.19 is a schematic elevation view of an example of an additively manufactured panel with integrated access holes;

[0051] Fig. 20 yes Fig.19 A schematic isometric view of an example of an additively manufactured panel;

[0052] Fig.21 is a schematic front view of an example of an additively manufactured panel having a plurality of integrated mounting holes;

[0053] Fig. 22 yes Fig.21 A schematic isometric view of an example of an additively manufactured panel;

[0054] Fig.23 is a schematic isometric view of an example of an additively manufactured panel having internal channels embedded in a skin;

[0055] Fig.24 is a flow chart illustrating an example of a method for additive manufacturing;

[0056] Fig.25 is a schematic block diagram of an example of an additive manufacturing apparatus;

[0057] Fig.26 is a flow chart illustrating an example of a method for additively manufacturing a panel;

[0058] Fig. 27 is a flowchart of an example of an aerospace vehicle manufacturing and maintenance method;

[0059] Fig.28 is a schematic block diagram of an example of an aerospace vehicle; and

[0060] Fig.29 is a schematic isometric view of an example of an additively manufactured panel with integrated ducts extending between skins. DETAILED DESCRIPTION

[0061] Various aspects and examples of additively manufactured aerospace panels with truss structures and related methods are described below and shown in the relevant figures. Unless otherwise stated, additively manufactured aerospace panels and / or their various components according to the present invention may, but are not required to, include at least one of the structures, components, functions and / or variations described, illustrated and / or incorporated herein. In addition, unless expressly excluded, the process steps, structures, components, functions and / or variations described, illustrated and / or incorporated herein in conjunction with the present invention may be included in other similar devices and methods, including interchangeability between the disclosed examples. The following description of various examples is merely illustrative in nature and is in no way intended to limit the present disclosure, its application or use. In addition, the advantages provided by the examples described below are illustrative in nature, and not all examples provide the same advantages or the same degree of advantages.

[0062] This detailed description includes the following sections, which follow immediately below: (1) Overview; (2) Examples, Components, and Alternatives; (3) Illustrative Combinations and Additional Examples; (4) Advantages, Features, and Benefits; (5) Conclusion. The Examples, Components, and Alternatives section is further divided into subsections A through H, each of which is labeled accordingly.

[0063] Overview

[0064] Typically, an additively manufactured aerospace panel according to the present invention comprises two skins connected by a truss structure. The panel is a single additively manufactured unit. The panel may also be described as a sandwich structure, a sandwich panel, or a composite material of a sandwich structure having two surface sheets connected by one or more core structures.

[0065] Figure 1A is a schematic diagram of an example of an aerospace vehicle 102, such as a spacecraft. In the illustrated example, aerospace vehicle 102 is depicted as a satellite, such as a communications satellite. In other examples, aerospace vehicle 102 may be a commercial airplane, a helicopter, a high-speed aircraft, an astronomical space observatory, a launch vehicle, an orbiting space station, and / or any vehicle that travels through the sky or through space.

[0066] In one or more examples, the aerospace vehicle 102 includes a body 104. The body 104 generally serves as the primary structure of the aerospace vehicle 102. The body 104 includes one or more additively manufactured truss panels including panels 100 ( Figures 1B to 1D ). The panel 100 may be used in an interior or exterior structure of an aerospace vehicle 102, and / or may be used in an auxiliary structure, a removable module, an equipment housing, and / or any suitable structure of the aerospace vehicle 102. Advantageously, in some examples, the panel 100 may include features configured for the challenges of a space environment.

[0067] Reference now Figures 1B to 1D , these figures schematically illustrate examples of a portion of a panel 100. In one or more examples, the panel 100 includes a first skin 110, a second skin 112, and a truss structure 114. The first skin 110 is spaced apart from the second skin 112.

[0068] In one or more examples of the panel 100, the first skin 110 and the second skin 112 are at least substantially parallel to each other (e.g., Figure 1B In one or more examples of the panel 100, at least a portion of the first skin 110 and at least a portion of the second skin 112 are not parallel to each other (e.g., Figure 1C In one or more examples of the panel 100, the first skin 110 and the second skin 112 are concentric with each other (eg, Figure 1D ).

[0069] In one or more examples of the panel 100 , the first skin 110 and the second skin 112 are joined together on at least one edge.

[0070] In one or more examples, the panel 100, the first skin 110, and the second skin 112 can be understood to have a planar extent. As an example, when viewed along at least an orthogonal axis or direction, the panel 100, the first skin 110, and the second skin 112 are generally planar (e.g., Figure 1B ). For example, panel 100 can take the form of a flat panel. In one or more examples, panel 100, first skin 110, and second skin 112 have curved and / or more complex geometries. As an example, panel 100, first skin 110, and / or second skin 112 are non-planar or include a degree of curvature or contour in one or more directions (e.g., Figure 1C and Figure 1D ).

[0071] In one or more examples, the truss structure 114 is connected to the first skin 110 and the second skin 112. The first skin 110 and the second skin 112 are in turn connected to each other through the truss structure 114. The truss structure 114 includes a plurality of truss members 118. In one or more examples, opposite ends of one or more truss members 118 are coupled to the first skin 110 and the second skin 112. In one or more examples, opposite ends of each truss member 118 are integral with the first skin 110 and the second skin 112, so that the first skin 110, the second skin 112, and the truss structure 114 together form a single integral jointless structure.

[0072] In one or more examples, the truss structure 114 includes an array of core structures 116. Each core structure 116 includes or takes the form of a frame of truss members 118 having any suitable geometry. In one or more examples, the geometry of the core structure 116 is uniform across the panel 100. In one or more examples, the geometry of the core structure 116 varies depending on the location in the panel 100. For example, the core structure 116 may vary depending on the expected non-uniform loading of the panel 100, and / or the core structure 116 may vary depending on the curvature of the panel 100, the first skin 110, and / or the second skin 112. In one or more examples, the core structures 116 are arranged in a grid, a repeating pattern, and / or in any effective manner.

[0073] In one or more examples of the panel 100, at least one of the first skin 110 and / or the second skin 112 has at least one grid region 120. At least one grid region 120 defines or takes the form of a grid 128 (e.g., a grid structure). Generally, in one or more examples, the grid 128 of the grid region 120 is configured to eliminate auxiliary printing supports during the additive manufacturing process of the panel 100. The grid 128 of the at least one grid region 120 includes a grid formed by grid members 122 and an array formed by openings 124. The grid 128 includes or takes the form of a pattern or structure made of strips of material (e.g., grid members 122) that cross each other, thereby leaving holes (e.g., openings 124) therebetween. In one or more examples, the strips of material (e.g., grid members 122) of the grid 128 cross each other in the form of a grid, vertically, diagonally, or a combination thereof.

[0074] In one or more examples, the lattice 128 includes a plurality of lattice reinforcements 136. In one or more examples, each lattice reinforcement 136 is disposed on an inner surface of the lattice 128. For example, the lattice reinforcements 136 are coupled to or integrated with the lattice members 122. The lattice reinforcements 136 provide stiffness and structural rigidity to the lattice members 122. In one or more examples, the lattice reinforcements 136 increase the thickness of the lattice 128 along each lattice member 122.

[0075] In one or more examples, at least one of the first skin 110 and the second skin 112 further includes at least one skin region 126. The skin region 126 includes or takes the form of a solid sheet structure made of a continuous material without holes or openings. Figures 1B to 1D In the example shown, the first skin 110 and the second skin 112 each include at least one grid region 120 and at least one skin region 126 .

[0076] In one or more examples, the panel 100 is additively manufactured or 3D printed as a single integral structure. In this way, the panel 100 can also be described as a single piece. In other words, the first skin 110, the second skin 112 and the truss structure 114 are additively manufactured or printed together, and the panel 100 is formed by the printed material without joints or seams. As such, the panel 100 can have a build axis. When printing the panel 100, the material layer is deposited in a plane perpendicular to the construction axis. In one or more examples, the build axis is parallel to the planar extent of the first skin 110 and / or the second skin 112. In such an example, the panel 100 can also be described as printed with a vertically oriented first skin 110 and a second skin 112. Therefore, in such an example, the first skin 110, the second skin 112 and the truss structure 114 can all be printed simultaneously instead of sequentially.

[0077] In one or more examples, the truss members 118 of the truss structure 114 or each core structure 116 are oriented and / or shaped relative to the build axis so that the truss members 118 are self-supporting during printing. That is, each core structure 116 can be printed without the need for auxiliary supports or the removal of support material after printing. In one or more examples, the truss members 118 extend at an angle of no more than 45 degrees relative to the build axis. In one or more examples, the panel 100 includes additional structures and / or features. In such examples, each structure and / or feature can be oriented, shaped and / or configured to be self-supporting during printing. The panel 100 can be configured to be manufactured without post-processing, such as machining after printing.

[0078] In one or more examples, the panel 100 is customized according to the intended use, structural function and / or placement within an aerospace vehicle such as a spacecraft. Additive manufacturing can allow flexibility in the design of the panel 100 and a combination of localized features. In one or more examples, the panel 100 includes local thickening for structural reinforcement, heat diffusion and / or heat dissipation. In one or more examples, the panel 100 includes integrated conductors and / or attachment features, such as fastener engagement structures. In one or more examples, the truss structure 114 is configured to increase resistance to the expected main loading mode, or is configured to be non-uniform to match the expected load non-uniformity. Design flexibility and localized features may be particularly important for aerospace panels and the challenges of the space environment (e.g., radiation, micrometeorological and orbital debris (MMOD) impact) and thermal conditions.

[0079] Examples, Parts, and Alternatives

[0080] The following sections describe selected aspects of exemplary additively manufactured aerospace panels and related systems and / or methods. The examples in these sections are intended to be illustrative and should not be construed as limiting the overall scope of the present disclosure. Each section may include one or more different examples, and / or contextual or related information, functions, and / or structures.

[0081] A. Exemplary Aerospace Panels

[0082] See also Figures 2 to 5 (These figures schematically illustrate examples of a portion of a panel 100) which describes an exemplary aerospace panel (referred to herein as panel 100). Panel 100 is an example of an additively manufactured truss panel. Panel 100 includes a first skin 110 and a second skin 112. The first skin 110 and the second skin 112 are connected by a truss structure 114. In one or more examples of panel 100, at least one of the first skin 110 and / or the second skin 112 has at least one region defining a grid, referred to herein as a grid region 120. In one or more examples of panel 100, the grid region 120 includes a grid grid, referred to herein as a grid 128. The grid 128 includes a grid formed by grid members 122 and an array formed by openings 124. The boundaries of the grid region 120 can correspond to any combination of the following: being based on geometric features (e.g., the location of reinforcements) that form the basis of the first skin 110 and / or the second skin 112; being positioned to enhance desired local properties of the panel 100; or being arbitrarily positioned as needed to meet overall panel design constraints.

[0083] exist Figures 2 to 5 In the example shown, the first skin 110 and the second skin 112 are generally planar and parallel to each other, and therefore, the panel 100 is generally planar. However, in other examples, the first skin 110 and the second skin 112 may be non-planar and / or non-parallel (e.g., Figure 1C and Figure 1D shown). Figures 2 to 5 Examples of different configurations of the grid regions 120 and the skin regions 126 of the first skin 110 and / or the second skin 112 are shown.

[0084] like Figure 2 As shown, in one or more examples, the first skin 110 is formed entirely of the grid region 120. In other words, the first skin 110 forms a continuous grid surface sheet of the panel 100. The second skin 112 is formed entirely of the skin region 126. In other words, the second skin 112 forms a continuous solid surface sheet of the panel 100.

[0085] like Figure 3As shown, in one or more examples, the first skin 110 is formed entirely of the grid region 120. In other words, the first skin 110 forms a continuous grid surface sheet of the panel 100. The second skin 112 is formed entirely of the grid region 120. In other words, the second skin 112 forms a continuous grid surface sheet of the panel 100.

[0086] like Figure 4 As shown, in one or more examples, at least one of the first skin 110 and the second skin 112 (eg, Figure 4 1 and 1 . The first skin 110 in the embodiment of the present invention includes or is formed by a grid region 120 and a skin region 126. In the example shown, the first skin 110 includes two portions (e.g., two skin regions 126) formed by skin regions 126, while the remaining portion of the second skin 112 is formed by the grid region 120. In the example shown, the skin region 126 is located on the inner boundary of the first skin 110 and is surrounded by the grid region 120. However, in other examples, the first skin 110 and / or the second skin 112 may have any number of skin regions 126, the skin regions 126 may be disposed at any suitable position along the extension of the first skin 110 and / or the second skin 112, and the skin regions 126 may have any suitable size and / or two-dimensional geometry. In either of these examples, the grid region 120 and the skin region 126 share a boundary and extend from and / or between each other to form the extents of the first skin 110 and / or the second skin 112 .

[0087] like Figure 5 As shown, in one or more examples, at least one of the first skin 110 and the second skin 112 (eg, Figure 5 The first skin 110 in the embodiment includes or is formed by a grid region 120 and a skin region 126. In the example shown, the first skin 110 includes a border portion formed by the skin region 126, and the remaining inner portion of the second skin 112 is formed by the grid region 120. In the example shown, the skin region 126 is positioned along the perimeter of the first skin 110 and forms the perimeter of the first skin 110, and surrounds the grid region 120. However, in other examples, any one or more of the perimeters of the first skin 110 and / or the second skin 112 may be completely formed by the grid region 120, or may have a portion formed by the skin region 126 and a portion formed by the grid region 120. In addition, Figure 5 The illustrated example may also include one or more skin regions 126 located on the interior portion and surrounded by a perimeter portion formed by skin regions 126 .

[0088] In other examples not shown, the grid regions 120 and the skin regions 126 of the first skin 110 and / or the second skin 112 may have any of a variety of patterns, layouts, or configurations. The pattern, layout, or configuration of the one or more grid regions 120 and the one or more skin regions 126 may depend on the size of the panel 100, the end use or application of the panel 100, the attachment location of the panel 100 to another structure, etc.

[0089] like Figures 2 to 5 As shown, regardless of the layout or configuration of the grid regions 120 and the skin regions 126 of the first skin 110 and / or the second skin 112, the first skin 110 and the second skin 112 are connected to the truss structure 114 and are connected to each other through the truss structure 114. In one or more regions of the first skin 110 and / or the second skin 112 formed by the skin regions 126, the ends of the truss members 118 are coupled to or integrated with the skin regions 126. In one or more regions of the first skin 110 and / or the second skin 112 formed by the grid regions 120, the ends of the truss members 118 are coupled to or integrated with the grid regions 120.

[0090] like Figures 2 to 5 As shown, in an example of a panel 100 having at least one grid region 120, a grid 128 of the grid region 120 includes a plurality of grid members 122 arranged in a grid or otherwise intersecting or crossing each other (e.g., vertically and / or diagonally) to form a plurality of openings 124 arranged in an array between the grid members 122. One end of each truss member 118 of the truss structure 114 is coupled to or integrated with the first skin 110 or the second skin 112 at a grid node 130 of the grid region 120. In one or more examples, one of the plurality of grid nodes 130 of the grid region 120 is located at an intersection of two or more lattice members 122 of the grid 128. For example, in a grid, each lattice member 122 extends vertically or diagonally between two grid nodes 130.

[0091] like Figure 2 As shown, in the example of a panel 100 having at least one skin region 126 , one end of each truss member 118 of the truss structure 114 is coupled to or integrated with the first skin 110 or the second skin 112 at a skin node 134 of the skin region 126 .

[0092] like Figure 2As shown, in an example of the panel 100 in which the lattice region 120 of the first skin 110 is opposite the skin region 126 of the second skin 112, each of the lattice nodes 130 of the first skin 110 is substantially aligned with one of the skin nodes 134 of the second skin 112 along an axis perpendicularly passing through the first skin 110 and the second skin 112. In one or more examples, each truss member 118 extends between the lattice nodes 130 of the first skin 110 and the skin nodes 134 of the second skin 112. In one or more examples, each truss member 118 extends diagonally between the lattice nodes 130 of the first skin 110 and the skin nodes 134 of the second skin 112.

[0093] like Figure 3 As shown, in the example of the panel 100 in which the grid region 120 of the first skin 110 is opposite the grid region 120 of the second skin 112, each of the grid nodes 130 of the first skin 110 is substantially aligned with one of the grid nodes 130 of the second skin 112 along an axis perpendicularly passing through the first skin 110 and the second skin 112. In one or more examples, each truss member 118 extends between the grid nodes 130 of the first skin 110 and the grid nodes 130 of the second skin 112. In one or more examples, each truss member 118 extends diagonally between the grid nodes 130 of the first skin 110 and the grid nodes 130 of the second skin 112.

[0094] See again Figure 2 In examples of the panel 100 where the first skin 110 or the second skin 112 includes at least one skin region 126, the skin region 126 may further include a plurality of skin reinforcements 132. Each skin reinforcement 132 is coupled to or integrated with the skin region 126 and extends between two skin nodes 134. In one or more examples, each skin reinforcement 132 extends diagonally between the two skin nodes 134.

[0095] B. Exemplary Pyramid Truss Aerospace Panel

[0096] Reference now Figures 6 to 9 , this section describes an exemplary pyramidal truss aerospace panel, referred to herein as panel 200. Panel 200 is an example of an additively manufactured truss panel, which is described herein above and referred to as panel 100. Panel 200 includes a first skin 210 and a second skin 212. The first skin 210 and the second skin 212 are connected by a truss structure 214. The first skin 210 is a first skin 110 (e.g., Figures 1B to 5 ). The second skin 212 is an example of the second skin 112 (e.g., Figures 1B to 5). Truss structure 214 is an example of truss structure 114 (e.g., Figures 1B to 5 ) example.

[0097] Reference Figure 6 (This figure shows an example of a panel 200.) In one or more examples, at least one of the first skin 210 and / or the second skin 212 has at least one grid region 250 in common. The grid region 250 is a grid region 120 (e.g., Figures 1B to 5 ). In one or more examples, the grid region 250 includes a grid 251. The grid 251 is a grid 128 (e.g., Figures 2 to 5 ) is an example of lattice members 251. Grid 251 includes a grid formed by grid members 254 and an array formed by openings 252. Grid members 254 are examples of grid members 122, and openings 252 are openings 124 (e.g., Figures 2 to 5 ) example.

[0098] The boundaries of the lattice regions 250 may correspond to any combination of: being based on geometric features of the skins 210, 212 (e.g., locations of stiffeners); being positioned to enhance desired local properties of the panel 200; or being positioned arbitrarily as needed to meet overall panel design constraints. The truss structures 214 may be configured to increase selected strength values ​​of the panel 200, such as shear resistance, tension resistance, or buckling resistance. In one or more examples, the truss structures 214 are configured to resist buckling loads.

[0099] In one or more examples of panel 200, at least one of first skin 210 and / or second skin 212 has at least one skin region 256. Figure 6 In the illustrated example, a portion of the second skin 212 includes a skin region 256 , and a portion of the second skin 212 includes a grid region 250 .

[0100] As further described below, each of the first skin 210, the second skin 212, and the truss structure 214 is shaped, characterized, and / or configured according to desired characteristics of the panel 200. The panel 200 can be configured for use in any aerospace vehicle. In one or more examples, the panel 200 is configured for use in a spacecraft. The panel 200 can be used as a structural component, as part of a thermal management system, as a radiation shield, and / or as a micrometeoroid and orbital debris (MMOD) shield for, for example, a spacecraft.

[0101] In one or more examples, the panel 200 includes any one or more materials suitable for additive manufacturing. These materials include, but are not limited to, polymers, gypsum, ceramics, metals, or composite materials. Polymer materials include thermoplastics (e.g., polyvinyl alcohol (PVA), polydimethylsiloxane (PDMS), polyetherketoneketone (PEKK), polylactic acid (PLA), nylon, acrylonitrile butadiene styrene (ABS) plastics, polycarbonate (PC), polyetherimide (PEI), polyimide (PI), polystyrene (PS), polytetrafluoroethylene (PTFE), acrylic acid (e.g., poly(methyl methacrylate)), polypropylene (PP), polyethylene (PE)), thermosetting plastics (e.g., photopolymer resin, epoxy resin), hydrogel, or any combination thereof. Metals include any high-strength, high-temperature metals or metal alloys, such as aluminum and its alloys, titanium and its alloys, niobium and its alloys, chromium-nickel-inconel alloys, or any combination thereof. In one or more examples, the panel 200 includes a laser-sintered metal alloy and is manufactured by direct laser metal sintering. In one or more examples, aluminum alloys may provide a favorable strength-to-weight ratio and provide efficient heat dissipation and / or removal.

[0102] Manufacturing the first skin 210, the second skin 212, and the truss structure 214 as a unitary (e.g., metal) structure can improve the thermal performance and heat removal of the panel by removing the impedance caused by the adhesive material in the traditionally manufactured sandwich panel. Such thermal performance is particularly beneficial for thermal management in the space environment. Additive manufacturing of the first skin 210 and the second skin 212 including at least one grid region 250 reduces the weight, material, cost, and cycle time associated with manufacturing the panel 200.

[0103] In one or more examples, panel 200 is approximately half an inch thick and 3.5 inches wide by 6 inches long. The size of panel 200 may be limited by the capacity of the equipment used to manufacture panel 200. In order to form a panel 200 having a desired size that exceeds the capacity of the selected additive manufacturing equipment, multiple panels (e.g., panel 200) may be printed separately and connected together. For example, panel 200 may be welded, bonded, and / or fastened to another panel as described herein.

[0104] Still reference Figure 6In one or more examples, each of the first skin 210 and the second skin 212 is planar and rectangular. Each of the first skin 210 and the second skin 212 has an outer surface 218 and an inner surface 220 opposite and parallel to the outer surface 218. In one or more examples, the first skin 210 is parallel to the second skin 212. In other examples, at least a portion of the first skin 210 and at least a portion of the second skin 212 are non-parallel. In one or more examples, each of the first skin 210 and the second skin 212 has a uniform thickness. In one or more examples, each of the first skin 210 and the second skin 212 is the same. In one or more examples, each of the first skin 210 and the second skin 212 has a thickness of approximately 0.02 inches. In one or more examples, as discussed further below in Section D, one or both of first skin 210 and second skin 212 can vary in thickness and / or one of first skin 210 or second skin 212 can have a greater thickness than the other.

[0105] In one or more examples, the panel 200 has a main axis 222 extending parallel to the first skin 210 and the second skin 212. In one or more examples, the main axis 222 is parallel to the long side of the rectangular shape of the first skin 210 and the second skin 212. In one or more examples, the panel 200 is additively manufactured according to the main axis 222 (e.g., along the main axis 222 or in the direction of the main axis 222), and the main axis 222 can also be described as a build axis or a vertical axis. In other words, the panel 200 is printed so that the main axis 222 is aligned with the build direction of the additive manufacturing device. For example, the panel 200 is printed onto the build plate by depositing a layer of material parallel to the build plate. In such an example, the panel 200 is printed with the main axis 222 perpendicular to the build plate.

[0106] Because the main axis 222 is parallel to the first skin 210 and the second skin 212, the first skin 210 and the second skin 212 can be described as being printed vertically. Each of the outer surface 218 and the inner surface 220 of the first skin 210 and the second skin 212 can extend in the build direction throughout the printing process. In the example of the first skin 210 and the second skin 212 with a grid area 250, the main axis of the grid area 250 is aligned with the main axis of the corresponding one of the first skin 210 and the second skin 212, and the grid 251 of the grid area 250 extends in the build direction. Such an orientation can allow the grid area 250 of the first skin 210 and the second skin 212 to be printed without auxiliary supports, with a good surface finish, and with limited warping. This orientation can also reduce the footprint size of the panel 200. Additive manufacturing equipment or 3D printers typically have a limited printing area. For example, a printer may have a limited build plate surface area. Orienting the panel 200 vertically during printing may increase efficiency by allowing multiple panels to be printed simultaneously in a single deposition run.

[0107] Reference Figure 7 and Figure 8 and Fig. 9 , Figure 7 An example of a portion of a panel 200 is shown, Figure 8 and Fig. 9 An example of a truss structure 214 of the panel 200 is shown. The truss structure 214 includes a plurality of truss members 224. The truss members 224 are truss members 118 (e.g., Figures 1B to 5 ). The truss members 224 are coupled to or integrated with the first skin 210 and the second skin 212. In one or more examples, each truss member 224 is substantially cylindrical in shape. In other examples, each truss member 224 has any other suitable cross-sectional shape.

[0108] In one or more examples, the truss members 224 extend between nodes 226 of the first skin 210 and nodes 226 of the second skin 212. In one or more examples, each truss member 224 extends between nodes 226 on the inner surface 220 of the first skin 210 and nodes 226 on the inner surface 220 of the second skin 212. The nodes 226 are lattice nodes 130 and / or skin nodes 134 (e.g., Figures 2 to 5 ) example.

[0109] In one or more examples of the panel 200, at least one of the first skin 210 and / or the second skin 212 includes at least one grid region 250. In one or more examples, the remaining areas of the first skin 210 and the second skin 212 include skin regions 256. Figure 7 In the example shown, the second skin 212 includes a lattice region 250 and a skin region 256. The lattice region 250 includes a lattice 251. The lattice 251 includes lattice members 254. The lattice members 254 intersect or cross each other to form openings 252. In one or more examples, the lattice members 254 intersect or cross in a grid pattern, vertically, diagonally, or a combination thereof. In one or more examples, the lattice 251 also includes a lattice reinforcement 260 extending along the lattice members 254 and integrated with the lattice members 254.

[0110] In one or more examples, the truss structure 214 includes a plurality of reinforcements 228. The reinforcements 228 are skin reinforcements 132 (e.g., Figure 2 ) and / or grid reinforcement 136 ( Figure 3 ). In one or more examples, the stiffener 228 is non-planar. In one or more examples, the stiffener 228 is triangular. In one or more examples, at least one stiffener 228 is disposed on (e.g., coupled to or integrated into) a skin region 256, such as an inner surface 220 of the first skin 210 or an inner surface 220 of the second skin 212. In these examples, the stiffener 228 may be referred to as a skin stiffener 262. In one or more examples, at least one stiffener 228 is disposed on (e.g., coupled to or integrated into) a grid region 250, such as an inner surface 220 of the first skin 210 or an inner surface 220 of the second skin 212. In these examples, the stiffener 228 may be referred to as a grid stiffener 260.

[0111] In one or more examples, each stiffener 228 has a maximum thickness of approximately 0.04 inches, or twice the thickness of the first skin 210 and / or the second skin 212. In one or more examples, the maximum thickness of the stiffener 228 is also approximately equal to the diameter of the truss member 224. The stiffeners 228 and truss members 224 can have any desired thickness or diameter.

[0112] In one or more examples, at least some of the lattice stiffeners 260 of the lattice 251 of the lattice region 250 correspond to at least some of the stiffeners 228 of the truss structure 214. In these examples, the thickness of the lattice members 254 is approximately 0.02 inches, and the thickness of the lattice stiffeners 260 is approximately 0.04 inches or twice the thickness of the lattice members 254, both of which are consistent with the thickness of the first skin 210 and / or the second skin 212 (including any skin stiffeners 262 associated with the skin region 256). The size of the stiffeners 228 and / or truss members 224 can be selected based on the desired structural properties of the panel 200.

[0113] In one or more examples, each node 226 is located at one of the stiffeners 228. The stiffeners 228 can improve the structural properties of the first skin 210 and the second skin 212, such as stiffness and buckling stability, and can strengthen the connection between the truss members 224 and the first skin 210 and the second skin 212. Although not necessarily corresponding directly to the skin stiffeners 262, the lattice stiffeners 260 can also improve and customize the structural properties of the lattice regions 250 of the first skin 210 and / or the second skin 212 while further reducing their weight.

[0114] Within the lattice region 250, each lattice node 255 is located at each intersection of a lattice member 254, a stiffener 228 (e.g., a lattice stiffener 260), and / or a truss member 224. The lattice node 255 is a lattice node 130 (e.g., Figures 2 to 5 ). Within skin region 256, each skin node 258 is located at an intersection of a stiffener 228 (e.g., skin stiffener 262) and / or a truss member 224. Skin nodes 258 are examples of skin nodes 134 (e.g., Figures 2 to 5 ).

[0115] In one or more examples, the lattice reinforcement 260 includes a portion of the lattice member 254 (e.g., forming a lattice skin of the panel 200) and an integral non-planar support member extending along and protruding from the lattice member 254. In one or more examples, each integral support member (e.g., the lattice reinforcement 260) is disposed on an inner surface of the lattice 251. In one or more examples of the lattice 251, the integral non-planar support member of the lattice reinforcement 260 is a triangular support member (e.g., having a triangular cross-sectional shape).

[0116] In one or more examples, the thickness of the grid 251 (e.g., grid skin) can be different than the skin of the skin region 256 outside the grid region 250 to meet material strength requirements (e.g., thicker, the same, or thinner). For some grids 251, the grid member thickness of the grid region 250 can be the same as the corresponding skin thickness of the skin region 256 where the grid region 250 is located.

[0117] In one or more examples of the panel 200, the integral non-planar stiffener supports for the lattice stiffeners 260 may have a larger cross-section, the same cross-section, or a smaller cross-section than the corresponding skin stiffeners 262. In some panels, the integral non-planar stiffener supports for the stiffeners 228 have the same cross-sectional area.

[0118] For the skin region 256 and the grid region 250, the inclusion of the reinforcement 228 can allow the thickness of the skin 210, 212 to be reduced without sacrificing the desired structural properties. Reducing the thickness of the skin 210, 212 or other portions of the panel 200 or removing multiple portions of the skin material (e.g., by an array formed by the openings 252 of the grid 251) can reduce the overall weight, material cost, and printing time of the panel 200. The non-planar cross-sectional shape of the reinforcement 228 can provide effective reinforcement of the first skin 210 and the second skin 212 with limited material. The reinforcement 228 can also improve the printability of relatively thin examples of the first skin 210, the second skin 212, and the truss structure 214. In other words, the reinforcement 228 can reduce or prevent adverse results, such as warping or cracking that may occur when additively manufacturing thin or slender structures.

[0119] In one or more examples, the reinforcements 228, such as the lattice reinforcements 260 and / or the skin reinforcements 262, are configured to be self-supporting during printing of the panel 200. More specifically, the cross-sectional shape (e.g., triangular) of the reinforcements 228 is shaped and oriented to allow for self-support. In addition to the primary axis 222, the panel 200 also has a secondary axis 230. The primary axis 222 may also be described as a vertical axis, and the secondary axis 230 may also be described as a horizontal axis. The secondary axis 230 is perpendicular to the primary axis 222 and perpendicular to the first skin 210 and the second skin 212. As shown in FIG. Figure 7 As shown, each side of the triangular cross-sectional shape of an applicable reinforcement 228 (such as a lattice reinforcement 260 and / or a skin reinforcement 262) extends at a reinforcement angle 232 relative to the minor axis 230. The angle 232 may be at least approximately 35 degrees. Figure 7 In the example shown, angle 232 is approximately 40 degrees.

[0120] In one or more examples, the reinforcement 228 (such as the grid reinforcement 260 and / or the skin reinforcement 262) is a triangular reinforcement (e.g., having a triangular cross-sectional shape). In one or more examples, the reinforcement 228 (such as the grid reinforcement 260 and / or the skin reinforcement 262) has an isosceles triangle cross-sectional shape, and the angle 232 matches on each side. In one or more examples, the reinforcement 228 (such as the grid reinforcement 260 and / or the skin reinforcement 262) has an unequal cross-sectional shape or other suitable cross-sectional shape. In such an example, the surface of the reinforcement 228 (such as the grid reinforcement 260 and / or the skin reinforcement 262) facing downward relative to the built orientation of the panel 200 may form an angle of at least approximately 35 degrees relative to the secondary axis 230.

[0121] Reference Figure 8 and Fig. 9 In one or more examples, the truss structure 214 includes a plurality of core pyramidal frames 234 arranged in a grid or array. Figure 8 and Fig. 9 An example of one of the core pyramid frames 234 is shown, referred to herein as a core pyramid 236. The core pyramid 236 includes four truss members 224. Each truss member 224 extends from a separate base node 238 to a single common upper node 240. The base node 238 is disposed at the corner of a square formed by four sections of reinforcement members 228. In one or more examples, the base node 238 is an example of a node 226, and the upper node 240 is an example of one of the nodes 226.

[0122] refer to Figure 8 and Fig. 9 In one or more examples, the core pyramid 236 is oriented with the base node 238 on the first skin 210 and the upper node 240 on the second skin 212. The skin region 256 (e.g., Figure 8 ) is the base node 238 within the skin node 258 ( Figure 7 ) example. The grid area 250 (e.g., Fig. 9 ) is the base node 238 within the grid node 255 ( Figure 7 ) example. The grid area 250 (e.g., Figure 8 and Fig. 9 ) is the upper node 240 in the grid node 255 ( Figure 7 ). The upper node 240 within the skin region 256 is the skin node 258 ( Figure 7 ) example.

[0123] In one or more examples, in the grid area 250 (e.g., Figure 8 and Fig. 9) The reinforcement member 228 extending from the upper node 240 is a grid reinforcement member 260 ( Figure 7 ). The reinforcement 228 extending from the upper node 240 in the skin region 256 is a skin reinforcement 262 ( Figure 7 ). In the skin region 256 (e.g., Figure 8 ) The reinforcement member 228 extending from the base node 238 is a skin reinforcement member 262 ( Figure 7 ). In the grid area 250 (e.g., Fig. 9 ) The reinforcement member 228 extending from the base node 238 is a lattice reinforcement member 260 ( Figure 7 ) example.

[0124] In one or more examples, the core pyramid 236 can be described as having a base at the first skin 210 and an apex at the second skin 212 (e.g., as shown in FIG. Figure 7 250 ). Alternatively, the truss members 224 of the truss structure 214 can be viewed as an array of core pyramids 236 (e.g., core pyramid frames 234), each core pyramid 236 having a base at the second skin 212 and an apex at the first skin 210. The panel 200 can thus have a symmetrical response to loads. In the portion of the skins 210, 212 within the grid region 250, the description of the core pyramids 236 is the same, except that the nodes within the grid region 250 are replaced by grid nodes 255 of the grid 251.

[0125] In one or more examples, each core pyramid 236 is configured to be self-supporting during printing. More specifically, the truss members 224 of the core pyramid 236 each extend at a selected angle to allow for self-support. Figure 7 As shown, the first truss angle 242 is located between the truss member 224 and the minor axis 230. The first truss angle 242 is located between the major axis 222 ( Figure 6 ) and secondary axis 230( Figure 7 ) is defined in a plane defined by the primary axis 222. In a plane perpendicular to the primary axis 222 but including the secondary axis 230, a second truss angle (not shown) is also defined between the truss member 224 and the secondary axis 230.

[0126] In one or more examples, each truss angle can be at least about 35 degrees and no greater than about 50 degrees. An angle of about 35 degrees or more can allow the truss member 224 to be printed without auxiliary supports. On the other hand, an angle of no greater than about 50 degrees can ensure that the truss structure 214 formed by the truss member 224 is sufficiently strong. In this example, the core pyramid 236 has a square base, and therefore the first truss angle 242 and the second truss angle are equal. In this example, the first truss angle 242 and the second truss angle are each about 40 degrees.

[0127] In one or more examples, each core pyramid 236 can also be configured according to the desired structural characteristics of the panel 200. For example, the first truss angle 242 and / or the second truss angle can be increased or decreased to adjust the desired stiffness of different examples of the panel 200. For another example, the diameter of each truss member 224 can be increased to improve panel strength or decreased to reduce the overall panel weight.

[0128] See also Fig.10 , which shows a cross-sectional view of an example of a panel 200 showing a checkerboard pattern of core pyramids 236 and an offset grid pattern of stiffeners 228. The first skin 210 is covered by an array of core pyramids 236 without gaps or overlaps, wherein the base of each core pyramid 236 meets the base of an adjacent core pyramid 236 along the stiffeners 228 of the first skin 210. Each core pyramid 236 shares a base node 238 with an adjacent core pyramid 236. At the side edges 244, the core pyramids 236 are truncated and each includes only two truss members 224.

[0129] In one or more examples, the plurality of reinforcements 228 on the first skin 210 form a first square grid 246. The second skin 212 ( Figure 3 ) form a second square grid 248. Each square grid 246, 248 includes a first plurality of parallel stiffeners and a second plurality of parallel stiffeners, the second plurality of parallel stiffeners intersecting the first plurality of parallel stiffeners and being orthogonal to the first plurality of parallel stiffeners. The first square grid 246 and the second square grid 248 are offset from each other so that the intersection of the first square grid 246 is vertically aligned with the center of the grid square of the second square grid 248. The intersection of the first square grid 246 coincides with the base node 238, and the intersection of the second square grid 248 coincides with the upper node 240 of the core pyramid 236.

[0130] C. Exemplary Cross Truss Aerospace Panel

[0131] Reference now Figures 11 to 13 , this section describes an exemplary cross-shaped truss aerospace panel, referred to herein as panel 300. Panel 300 is an example of an additively manufactured truss panel, which is described above and referred to as panel 100. Panel 300 includes a first skin 310 and a second skin 312. First skin 310 and second skin 312 are connected by a truss structure 314. First skin 310 is a first skin 110 (e.g., Figures 1B to 5 ). The second skin 312 is an example of the second skin 112 (e.g., Figures 1B to 5 ). Truss structure 314 is an example of truss structure 114 (e.g., Figures 1B to 5) example.

[0132] Reference Fig.11 , which shows an example of a portion of a panel 300. In one or more examples, at least one of the first skin 310 and / or the second skin 312 has at least one grid region 350. The grid region 350 is a grid region 120 (e.g., Figures 1B to 5 ). In one or more examples, the grid region 350 includes a grid 351. The grid 351 is a grid 128 (e.g., Figures 2 to 5 ) is an example of lattice members 351. Grid 351 includes a grid formed by grid members 354 and an array formed by openings 352. Grid members 354 are examples of grid members 122, and openings 352 are openings 124 (e.g., Figures 2 to 5 ) example.

[0133] In one or more examples of panel 300, at least one of first skin 310 and / or second skin 312 has at least one skin region 356. Skin region 356 is a portion of skin region 126 ( Figures 1B to 5 ). Fig.11 In the illustrated example, a portion of the second skin 312 includes a skin region 356 , and a portion of the second skin 312 includes a grid region 350 .

[0134] The boundaries of the lattice regions 350 can correspond to any combination of: being based on geometric features of the skins 310, 312 (e.g., the location of stiffeners); being positioned to enhance desired local properties of the panel 300; or being positioned arbitrarily as needed to meet overall panel design constraints. The truss structures 314 can be configured to increase selected strength values ​​of the panel 300, such as shear resistance, tension resistance, or buckling resistance. In one or more examples, the truss structures 314 are configured to resist buckling loads.

[0135] like Fig.11 As shown, in one or more examples, each of the first skin 310 and the second skin 312 is planar and rectangular, having an inner surface 320. The first skin 310 is parallel to the second skin 312. The truss structure 314 includes a plurality of cross-shaped or X-shaped truss members 324 extending between nodes 326 of the first skin 310 and nodes 326 of the second skin 312. In one or more examples, each truss member 324 extends between a node 326 on the inner surface 320 of the first skin 310 and a node 326 on the inner surface 320 of the second skin 312. The node 326 is a lattice node 130 and / or a skin node 134 (e.g., Figures 2 to 5 ) example.

[0136] like Fig.11As shown, in one or more examples, each truss member 324 extends between a pair of nodes 326 on the inner surface 320 of the first skin 310 and a pair of nodes 326 on the inner surface 320 of the second skin 312. In one or more examples, each truss member 324 includes four legs 325. In one or more examples, each truss member 324 is substantially cylindrical in shape. In other examples, each truss member 324 can have any suitable cross-sectional geometry. Each leg 325 extends from the node 326 to a central connection area 327 of the truss member 324.

[0137] In one or more examples, the truss structure 314 includes a plurality of circular bosses 328. Each boss 328 extends vertically from the inner surface 320 of the first skin 310 or the second skin 312. The circumferential edge of each boss 328 is rounded to improve the printability and self-support of the boss 328. In one or more examples, the boss 328 is located at each node 326. The bosses can facilitate and strengthen the connection between the truss member 324 and the skins 310, 312.

[0138] Reference Fig.12 and Fig.13 , these figures illustrate examples of a truss structure 314 of a panel 300. In one or more examples, the truss structure 314 includes a plurality of core box frames 334 arranged in a grid or array. Fig.12 and Fig.13 An example of one of the core box frames 334 is shown, referred to herein as a core box 336. The core box 336 includes four truss members 324 arranged in a square box shape, each truss member forming a side of the box. The nodes 326 define the corners of the box shape. One leg 325 of each of the two truss members 324 meets at each node 326. One leg 325 of each truss member 324 extends between a pair of diagonal nodes 326. For example, each leg 325 of the truss member 324 extends from a base node 362 to an upper node 364 diagonally opposite the base node 362. In one or more examples, the base node 362 is an example of a node 326, and the upper node 364 is an example of a node 326.

[0139] In one or more examples of the truss structure 314, at least a portion of the core box frame 334 can be located within the lattice region 350 and arranged in alignment with the grid of the lattice members 354 of the lattice 351. In one more example, the core box 336 is at least partially within the lattice region 350, such as the upper surface is within the lattice region 350 and the lower surface is not within the lattice region 350. In one or more examples of the truss structure 314 within the lattice region 350, the lattice 351 also includes lattice reinforcements 360 and lattice nodes 355, wherein the lattice nodes 355 define the corners of the box shape of the core box 336, wherein one leg 325 of each of the two truss members 324 meets at each lattice node 355.

[0140] In one or more examples, the core box 336 is oriented with the base node 362 on the first skin 310 and the upper node 364 on the second skin 312. Fig.12 ) is the base node 362 in the skin node 358 ( Fig.11 ). The grid area 350 (e.g., Fig.13 ) is the base node 238 within the grid node 355 ( Fig.11 ). The grid area 350 (e.g., Fig.12 and Fig.13 ) is the upper node 364 of the grid node 355 ( Fig.11 ). The upper node 364 within the skin region 356 is the skin node 358 ( Fig.11 ) example.

[0141] In one or more examples, the truss structure 314 includes a plurality of reinforcements 366. The reinforcements 366 are skin reinforcements 132 (e.g., Figure 2 ) and / or grid reinforcement 136 ( Figure 3 ). In one or more examples, the reinforcement 366 is non-planar. In one or more examples, the reinforcement 366 is triangular. In one or more examples, at least one reinforcement 366 is disposed on (e.g., coupled to or integrated into) a skin region 356, such as an inner surface 320 of the first skin 310 or an inner surface 320 of the second skin 312. In these examples, the reinforcement 366 may be referred to as a skin reinforcement 368. In one or more examples, at least one reinforcement 228 is disposed on (e.g., coupled to or integrated into) a grid region 250, such as an inner surface 220 of the first skin 210 or an inner surface 220 of the second skin 212. In these examples, the reinforcement 366 may be referred to as a grid reinforcement 360.

[0142] In one or more examples, in the grid area 350 (e.g., Fig.12 and Fig.13 The reinforcement member 366 extending between the upper nodes 364 in the ) is the grid reinforcement member 360 ( Fig.11 ). The reinforcement 366 extending between the upper nodes 364 in the skin region 356 is a skin reinforcement 368 ( Fig.11 ). In the skin region 356 (e.g., Fig.12 ) is a skin reinforcement 368 ( Fig.11 ). In the grid area 350 (e.g., Fig.13 ) is a reinforcement member 366 extending between the base nodes 362 in the lattice reinforcement member 360 ( Fig.11 ) example.

[0143] In one or more examples, the core boxes 336 of the core box frame 334 can be described as overlapping in the truss structure 314. That is, the core box 336 can be described as sharing each of the four truss members 324 with a corresponding one of the four adjacent core boxes 336 of the core box frame 334. The truss structure 314 can also be described as including a plurality of intersecting cylindrical truss members 324. Fig.12 and Fig.13 As shown, in one or more examples, each truss member 324 can be described as extending diagonally between a node 326 on the first skin 310 and a node 326 on the second skin 312. Fig.12 As shown, in one or more examples, each truss member 324 can be described as extending diagonally between a lattice node 355 of a lattice 351 of a lattice region 350 of a second skin 312 and a skin node 358 of a skin region 356 of a first skin 310. Fig.13 As shown, in one or more examples, each truss member 324 may be described as extending diagonally between a grid node 355 of a grid 351 of a grid region 350 of the second skin 312 and a grid node 355 of a grid region 350 of the first skin 310 .

[0144] In one or more examples, each core box 336 is configured to be self-supporting during printing. More specifically, the legs 325 of the core box 336 each extend at a selected angle to allow for self-support. Fig.11As shown, each leg 325 defines a truss angle 342 with the minor axis 330 of the panel 300. The minor axis 330 can be perpendicular to the build direction of the panel 300 and can be described as a horizontal axis. Each truss angle 342 can be at least about 35 degrees. In one or more examples, the sides of the core box 336 are square, and the truss angles 342 of the legs 325 of each truss member 324 are equal. In one or more examples, the truss members 324 can form rectangular sides of the core box 336, and the truss angles 342 between the legs 325 can be different. In one or more examples, the truss angle 342 of each leg 325 is about 45 degrees.

[0145] D. Exemplary Truss Panel Features

[0146] See also Figures 14 to 23 , which describes several examples of features of an exemplary trussed aerospace panel (referred to herein as panel 400). Panel 400 is an example of an additively manufactured trussed panel, which is described above and referred to as panel 100. Panel 400 includes a first skin 410 and a second skin 412. First skin 410 and second skin 412 are connected by a truss structure 414. First skin 410 is a first skin 110 (e.g., Figures 1B to 5 ). The second skin 412 is an example of the second skin 112 (e.g., Figures 1B to 5 ). Truss structure 414 is an example of truss structure 114 (e.g., Figures 1B to 5 ) example.

[0147] In one or more examples, each of the first skin 410 and the second skin 412 is planar and rectangular, having an outer surface 418 and an inner surface 420. In one or more examples, the first skin 410 is parallel to the second skin 412. In one or more examples, the first skin 410 and the second skin 412 are non-parallel. In one or more examples, the first skin 410 and the second skin 412 are concentric. In one or more examples, at least a portion or section of the first skin 410 and the second skin 412 are parallel, and at least another portion or section of the first skin 410 and the second skin 412 are non-parallel.

[0148] In one or more examples of the panel 400, at least one of the first skin 410 or the second skin 412 includes at least one grid region 490. The grid region 490 is a grid region 120 ( Figures 1B to 5 ) is an example of a grid region 490. The grid region 490 includes a grid 491. The grid 491 is a grid region 128 ( Figures 1B to 5) is an example of lattice members 491. Grid 491 includes a grid formed by grid members 493 and an array formed by openings 492. Grid members 493 are examples of grid members 122, and openings 492 are openings 124 (e.g., Figures 2 to 5 ). In one or more examples, the lattice 491 includes a lattice reinforcement 496 extending along or corresponding to the lattice member 493. In one or more examples, the lattice 491 includes a lattice node 495 ( Fig.14 ). Grid node 495 is a grid node 130 ( Figures 2 to 5 ) An example of a lattice member 493 and a lattice stiffener 496 extend through a lattice node 495 where they cross or otherwise meet.

[0149] In one or more examples of panel 400, at least one of first skin 410 and / or second skin 412 has at least one skin region 498. Skin region 498 is a portion of skin region 126 ( Figures 1B to 5 In one or more examples, a portion of the first skin 410 and / or the second skin 412 includes a skin region 498 and a grid region 490.

[0150] In one or more examples, the truss structure 414 includes a plurality of truss members 424 extending between nodes 426. The nodes 426 located within the skin region 498 can be referred to as skin nodes 497. The skin nodes 497 are the skin nodes 134 ( Figures 2 to 5 ) is an example of a grid node 426 located in a grid region 490. A grid node 495 is a grid node 130 ( Figures 2 to 5 ). In one or more examples, each truss member 424 extends between a node 426 on the inner surface 420 of the first skin 410 and a node 426 on the inner surface 420 of the second skin 412. In one or more examples, at least one truss member 424 extends between a lattice node 495 of a lattice of a lattice region 490 of the second skin 412 and a lattice node 495 of a lattice region 490 of the first skin 410. In one or more examples, at least one truss member 424 extends between a lattice node 495 of a lattice of a lattice region 490 of the second skin 412 and a skin node 497 of a skin region 498 of the first skin 410. In one or more examples, each truss member 424 can be substantially cylindrical in shape.

[0151] In one or more examples, the truss structure 414 includes core pyramids 434, each of which is formed by four truss members 424 and arranged in a grid, array, and / or chessboard. In one or more examples, the truss structure 414 includes core box frames, each of which is formed by four cross-shaped truss members and arranged in a grid, array, and / or chessboard.

[0152] Reference Fig.14 In one or more examples, the truss structure 414 includes a plurality of circular bosses 428. In one or more examples, each boss 428 extends at least approximately perpendicularly from the inner surface 420 of the first skin 410 or the second skin 412. The perimeter of each boss 428 is rounded to improve the printability and self-support of the boss 428. The boss 428 is located at each node 426. The boss 428 can facilitate and strengthen the connection between the truss member 424 and the skins 410, 412.

[0153] Fig.14 An example of a panel 400 customized for additional strength and stiffness by adding a third skin 450 and a second truss structure 452 is shown. In these examples, the truss structure 414 may also be referred to as a first truss structure 414. In one or more examples, the third skin 450 is planar and rectangular and parallel to the second skin 412, but spaced apart from the second skin 412. The third skin 450 has an outer surface 418 and parallel inner surfaces 420. In one or more examples, the third skin 450 has a uniform thickness, and the first skin 410, the second skin 412, and the third skin 450 are identical. In one or more examples, each skin 410, 412, 450 has a thickness of approximately 0.02 inches. In order to customize the mechanical properties of the panel, a grid 490 may also be introduced in different skin locations in any combination of the first skin 410, the second skin 412, or the third skin 450.

[0154] In one or more examples, the third skin 450 is connected to the second skin 412 by the second truss structure 452. The second skin 412 is sandwiched between the second truss structure 452 and the first truss structure 414. The outer surface 418 of the first skin 410 and the third skin 450 forms the outer surface of the panel 400.

[0155] In one or more examples, the second truss structure 452 is substantially the same as the first truss structure 414 and further includes a plurality of truss members 424 extending between nodes 426. Each truss member 424 extends between a node 426 on the outer surface 418 of the second skin 412 and a node 426 on the inner surface 420 of the third skin 450. In one or more examples, the second truss structure 452 includes a plurality of core pyramids 434, each core pyramid 434 is formed by four truss members 424, and is arranged in a grid, array, and / or checkerboard. In one or more examples, the second truss structure 452 includes a plurality of core box frames, each core box frame is formed by four cross-shaped truss members, and is arranged in a grid, array, and / or checkerboard.

[0156] In one or more examples, the nodes 426 on the outer surface 418 of the second skin 412 are aligned with the nodes 426 on the inner surface 420 of the second skin 412. The core pyramids 434 of the first truss structure 414 are aligned with the core pyramids 434 of the second truss structure 452. The relative alignment of the core pyramids 434 of the first truss structure 414 and the second truss structure 452 can be selected to provide a desired structural reinforcement or other structural interaction between the truss structures 414, 452.

[0157] In one or more examples, the third skin 450 can be substantially the same as the second skin 412 and / or the first skin 410. In one or more examples, the third skin 450 includes at least one skin region 498. In one or more examples, the third skin 450 includes at least one lattice region 490. In one or more examples, the third skin 450 can be different from the second skin 412 and / or the first skin 410. In some examples, the second truss structure 452 can be different from the first truss structure 414. The third skin 450 can have any desired thickness and / or curvature, and the second truss structure 452 can have any desired geometry. In one example, the second truss structure 452 can include a plurality of core box frames, such as those described in Example C and Figures 11 to 13 In one example, the second truss structure 452 may include a plurality of core pyramid frames, as described in Example B and Figures 6 to 10 In some examples, panel 400 may also include additional skin and truss structures.

[0158] Including the third skin 450 and the second truss structure 452 in the panel 400 can increase the moment of inertia of the panel while maintaining buckling stability. This modification is particularly desirable for foreign object debris (FOD), micrometeoroids and orbital debris (MMOD), or other impact shielding. This modification can also be used to increase the thickness of the panel 400 without reducing desired structural properties, such as buckling stability.

[0159] Reference Fig.15 , which shows an example of a panel 400 that is adjusted for local stiffness to have a variable core density. In the example shown, the panel 400 includes a first region 453 and a second region 455. Each region 453, 455 includes a first skin 410, a second skin 412, and a portion of a truss structure 414. In the first region 453, the truss structure 414 has a first core configuration 454, and in the second region 455, the truss structure 414 has a second core configuration 456. The first region 453 and the second region 455 meet at an interface 458 between the first core configuration 454 and the second core configuration 456. In one or more examples of the panel 400, at least one of the first skin 410 or the second skin 412 (the second skin 412 in the example shown) has a grid region 490 including a grid 491, the grid 491 having, for example, grid members 493, openings 492, grid reinforcements 496, and grid nodes.

[0160] In the first core configuration 454, the core pyramids 434 have a first density. In the second core configuration 456, the core pyramids 434 have a higher second density. In other words, each core pyramid 434 of the truss structure 414 has a base span dimension. In the first region 453, the core pyramids 434 have a first base span dimension AA, and in the second region 455, the core pyramids 434 have a second base span dimension BB. The first base span dimension AA is greater than the second base span dimension BB. In the example of a panel 400 having one or more grids 490 (grid regions), the density of the grids 490 may correspond to the density of the core pyramids 434 and have a distribution associated with the local span dimension AA of the first region and the local span dimension BB of the second region.

[0161] In one or more examples, the core pyramids 434 each have a square base. Thus, within each region 453, 455, the core density can be understood to be equal in each direction parallel to the plane of the skins 410, 412. In some examples, the truss structure 414 can include core pyramids 434 with rectangular bases and / or other geometric core structures. In such examples, the base span size, and therefore the density of the core structure, can vary depending on the direction.

[0162] In one or more examples, the interface 458 can be understood to extend linearly on the panel 400. Each region 453, 455 can constitute a rectangular section of the panel 400. In some examples, the regions 453, 455 can have a non-linear interface and / or any desired shape. For example, the first region 453 can have a generally circular shape and can be surrounded by the second region 455. The interface 458 can be along the boundary between the various core structures so that no core structure is divided by the interface.

[0163] The greater density of the second region 455 relative to the first region 453 may provide additional stiffness. However, the increased stiffness may have a trade-off of increased weight and material cost. Varying the density across the panel 400 may allow the stiffness of the panel to be adjusted locally. For example, the density of the truss core structure may be increased in regions expected to experience stronger or more frequent loads, while the density may be reduced in regions expected to experience limited loads.

[0164] See also Fig.16 , which shows an example of a panel 400 having a local thickening of the skins 410, 412. In the example shown, the panel 400 includes at least one reinforcement region 457. In the example shown, the reinforcement region 457 shown includes a respective thickening of the first skin 410 and the second skin 412. In one or more examples, the reinforcement region 457 may include a thickening of only one of the first skin 410 and the second skin 412, or the first skin 410 and the second skin 412 may be thickened to different degrees. In one or more examples, the reinforcement region 457 includes a grid region 490. In one or more examples, the reinforcement region 457 overlaps or includes both the grid region 490 and the skin region 498. In examples where the reinforcement region 457 includes at least a portion of the grid region 490, the thickness of the grid member 493 and / or the grid reinforcement member 496 is increased to correspond to the increase in the thickness of the skin.

[0165] In one or more examples, outside the reinforced region 457, the second skin 412 has a thickness CC. Within the reinforced region 457, the second skin 412 has an increased thickness DD. In one or more examples, the increased thickness DD extends inwardly relative to the second skin 412 so that the outer surface 418 of the second skin 412 remains flat throughout. At the outer boundary of the reinforced region 457, the second skin 412 includes a rounding 459 to provide a gradual transition between the two thicknesses. The rounding 459 can be configured to allow the reinforced region 457 to be printed without auxiliary supports. In one or more examples, the reinforced region 457 includes a matching thickening of the first skin 410. In some examples, where the reinforced region 457 may overlap with the grid region 490, the increased thickness of the grid members 493 and / or the grid reinforcements 496 extends inwardly relative to the corresponding first skin 410 and / or second skin 412. The grid members 493 and grid reinforcements 496 may be configured so that all reinforcement regions 457 within the grid region 490 are printed without auxiliary supports.

[0166] In one or more examples, the reinforcement region 457 can be understood to be generally square in shape. In some examples, the reinforcement region 457 can have non-linear boundaries and any desired shape. For example, the reinforcement region 457 can be rectangular, circular, and / or shaped to conform to adjacent structures of the panel 400 after the panel 400 is assembled into a structure (e.g., an aerospace vehicle).

[0167] In one or more examples, the reinforced region 457 can replace the shielding that typically includes a separate metal sheet or other material attached to the sandwich panel. For example, the reinforced region 457 can be configured as a radiation shield for an electronic device. In such an example, the reinforced region 457 can be shaped to match the shielded electronic device. The reinforced region 457 is additionally or alternatively configured for thermal management purposes. For example, the reinforced region 457 can extend from the heat output area of ​​the electronic device to the surrounding portion of the panel to facilitate the diffusion and discharge of heat generated by the device.

[0168] In one or more examples, additionally or alternatively, the reinforced region 457 can be configured for structural reinforcement of the panel 400. For example, the reinforced region 457 can be a thin strip adjacent to an edge of the panel 400 that is used for welding to another panel. The reinforced region 457 can compensate for strength loss in the heat affected zone of the weld joint. For another example, the reinforced region 457 can extend over a substantial area of ​​the second skin 412 to act as an integrated doubler. Such doublers can provide increased panel strength.

[0169] refer to Fig.17 and Fig.18, these figures show an example of a panel 400 with integrated enclosures. The integrated enclosures can replace the separate enclosures that are usually fixed to the sandwich panel. In the example shown, the panel 400 includes enclosures on each of the four edges. With respect to the build direction or build axis, the integrated enclosures of the panel 400 can be described as including an upper enclosure 460, a lower enclosure 462 and two side enclosures 464.

[0170] Fig.17 4 is a cross-sectional view of an example of a panel 400 cut along a plane parallel to the build axis, and shows a cross-sectional shape having an upper wall 460 and a lower wall 462. In one or more examples, the lower wall 462 comprises an initial print layer of the panel 400 and can be deposited directly onto the support of the build plate. Thus, the lower wall 462 is planar and perpendicular to the build axis and the skins 410, 412. In contrast, in one or more examples, the upper wall 460 comprises a final print layer of the panel 400. Thus, in order to print without auxiliary supports, the upper wall 460 has an arch, chamfer, or inverted V-shape.

[0171] Fig.18 4 is a cross-sectional view of an example of a panel 400 cut along a plane perpendicular to the build axis, and shows a cross-sectional shape having side walls 464. Each side wall 464 can extend parallel to the build axis of the panel. Thus, the side walls 464 are primarily planar. The side walls 464 include a small chamfer or radius at each corner where the side walls 464 connect to the lower wall 462 and the upper wall 460.

[0172] In one or more examples, each fence extends the full length of the corresponding edge of the panel 400. In some examples, the fence may extend only a portion of the length of the panel and / or may include breaks, openings, or holes. In some examples, the panel 400 may include only one, two, or three fences. The panel 400 may be designed, constructed, and / or utilized so that the additional local stiffness and / or strength generated by the fence can be utilized. For example, the panel 400 can be installed in the structure so that the upper fence 460 is close to the maximum expected load area to utilize the stiffness generated by the additional material included in the upper fence.

[0173] refer to Fig.19 and Fig. 20 , these figures show an example of a panel 400 having an integrated access hole 466. In one or more examples, the access hole 466 is located or disposed in a skin region 498 of at least one of the first skin 410 and / or the second skin 412 (e.g., in Fig.19In one or more examples, the access hole 466 is disposed in the skin region 498 of the second skin 412. In one or more examples, the access hole 466 is located or disposed in the grid region 490 of at least one of the first skin 410 and / or the second skin 412. In one or more examples, the access hole 466 is disposed in one of the skins 410, 412 in addition to any grid region 490.

[0174] In one or more examples, the access hole 466 extends from the outer surface 418 of the first skin 410 through the panel to the outside of the second skin 412. In one or more examples, the access hole 466 is circular and is defined by a generally cylindrical wall 468. Similar to the truss structure 414, the wall 468 connects the first skin 410 to the second skin 412. The wall 468 is disposed between the skins 410, 412 in an area of ​​the panel 400 that does not include the truss structure 414. That is, the wall 468 extends through a gap in the truss structure 414.

[0175] In one or more examples, the wall 468 includes an outer side 467 ( Fig.19 ) and inner 469( Fig. 20 ). The inner side 469 is cylindrical and defines the access hole 466. The outer side 467 is rounded so as to have a maximum diameter closest to each skin 410, 412 and a minimum diameter at a point in the middle of the skins 410, 412. The rounded shape of the outer side 467 can help support the wall 468 during printing, thereby allowing printing without auxiliary supports and maintaining the circularity of the access hole 466. The rounded shape of the outer side 467 can also provide a secure connection between the wall 468 and the skins 410, 412 and improve the stiffness and / or strength of the panel 400 near the access hole 466.

[0176] In the example shown, the access hole 466 is circular. In some examples, the access hole 466 can have a diamond shape, or can be shaped according to the intended use. As in the example shown, the inner side 469 and the outer side 467 of the access hole 466 can be different and can be configured to allow printing without auxiliary supports and within the desired limits of surface roughness.

[0177] In one or more examples, the panel 400 can include any suitable number of access holes 466 positioned as needed for access. For example, the access holes 466 can be used to pass cables, pipes, harnesses, and other accessories through the panel 400. For another example, the access holes 466 can be used for visual inspection or manual maintenance of the interior of the structure including the panel 400. The integration of the access holes 466 into the printed design of the panel 400 can replace the typical drilling of access holes in the finished sandwich panel.

[0178] refer to Fig.21and Fig. 22 , these figures show an example of a panel 400 having a plurality of integrated mounting holes 470. The holes 470 may be configured to facilitate assembly of multiple panels, mounting of modules or accessories to a panel, mounting of modules or accessories to structural members on opposite sides of a panel, and / or any desired mounting, fastening, and / or attachment.

[0179] In one or more examples, the hole 470 is located or disposed in the skin region 498 of at least one of the first skin 410 and / or the second skin 412 (e.g., in Fig. 22 In one or more examples, the hole 470 is disposed in the skin region 498 of the second skin 412. In one or more examples, the hole 470 is located or disposed in the grid region 490 of at least one of the first skin 410 and / or the second skin 412. In one or more examples, the hole 470 is disposed in one of the skins 410, 412 in addition to any grid region 490.

[0180] In one or more examples, each hole 470 extends from the outer surface 418 of the first skin 410 through the panel 400 to the outer surface 418 of the second skin 412. In one or more examples, the holes 470 are circular, and each hole is defined by a cylindrical wall 472. Similar to the truss structure 414, each wall 472 connects the first skin 410 to the second skin 412. The walls 472 are disposed between the skins 410, 412, each wall in an area of ​​the panel 400 that does not include the truss structure 414. That is, each wall 472 extends through a gap in the truss structure 414.

[0181] In one or more examples, each wall 472 includes an outer side and an inner side, similar to the access hole 466 ( Fig.19 and Fig. 20 ) on the outside and inside. The inside is cylindrical and defines a corresponding hole 470. The outside includes a rounding near each skin 410, 412 to provide a secure connection between the wall 472 and the skin 410, 412 and to increase the stiffness and / or strength of the panel 400 near the hole 470. Each wall 472 can be configured for printing without auxiliary supports. In some examples, the inside and / or outside can have a diamond cross-section or other desired shape.

[0182] In one or more examples, the panel 400 can include any appropriate number of holes 470, the size and position of which are determined according to the intended installation or other purpose. In this example, the panel 400 includes four holes 470, which are positioned to allow the square module to be fastened to the panel 400. Each hole 470 is sized to accommodate a bolt for installation. In some examples, the size of the hole 470 can be determined to receive a threaded bushing to allow threaded engagement with the panel 400.

[0183] refer to Fig.23 , which shows an example of a panel 400 with an integrated internal channel 474. In the example shown, the second skin 412 of the panel 400 has an increased thickness EE to allow for the integration of the channel 474. In this example, the thickness EE is approximately one quarter inch, and the channel 474 has a diameter of approximately 0.02 inches. The channel 474 may be described as being embedded in the second skin 412 and / or embedded between the second skin 412 and the first skin 410. The channel 474 is shown as having a circular cross-section, but may have any cross-sectional shape that allows for printing without auxiliary supports, including a diamond shape.

[0184] In one or more examples, passage 474 extends through skin 412 from first hole 476 to second hole 478 . Fig.17 The example of the channel 474 shown has an illustrative pattern including multiple turns and multiple branching paths. In some examples, the channel 474 may include a single continuous path, a dead end portion, a change in channel size and / or near the outer surface 418 or the inner surface 420 of the second skin 412, and / or any desired features. In the example shown, the holes 476, 478 are disposed in the edge portions of the second skin 412. In some examples, one or two holes 476, 478 may be disposed in different edges of the outer surface 418, the inner surface 420 and / or the second skin 412. In some examples, the panel 400 and / or the second skin 412 may also include additional structures and / or features configured to allow connection of a fluid management system.

[0185] In one or more examples, the channel 474 is located or disposed in the skin region 498 of at least one of the first skin 410 and / or the second skin 412 (e.g., in Fig.23 In one or more examples, the channel 474 is disposed in the skin region 498 of the second skin 412. In one or more examples, the channel 474 is disposed in one of the skins 410, 412 in addition to any grid region 490. In one or more examples, the channel 474 is routed around or along the grid region 490.

[0186] In one or more examples, the channel 474 can be configured according to the intended function of the channel 474. For example, the channel 474 can be configured to facilitate active cooling of equipment mounted adjacent to the panel 400. In such an example, the channel 474 can be configured to allow smooth flow of a selected coolant fluid and provide substantial exposure of the fluid to areas of the panel adjacent to the equipment by including a plurality of returns and / or parallel branches. For another example, the channel 474 can be configured to allow fuel or lubricant to be delivered through the panel 400. In such an example, the channel 474 can be configured to allow the fluid to flow quickly through the panel in a simple and direct path.

[0187] refer to Fig.29 , which shows an example of a panel 400 with an integrated duct 480. In one or more examples, the panel 400 includes a plurality of ducts 480 (e.g., Fig.29 4. In one or more examples, the ducts 480 are microtubes. In the example shown, the ducts 480 extend between and contact at least a portion of one or both of the first skin 410 and the second skin 412. In one or more examples, the ducts 480 contact the skin area 498 of one or both of the first skin 410 and the second skin 412. In one or more examples, the ducts 480 contact the grid area 490 of one or both of the first skin 410 and the second skin 412.

[0188] In one or more examples. The duct 480 is formed or defined by a first wall 482 and a second wall 484. The first wall 482 and the second wall 484 are connected to the first skin 410 and the second skin 412 and extend between them. In one or more examples, the first wall 482 and the second wall 484 extend side by side with each other to form or define a hollow interior 486 (e.g., a channel) of the duct 480. In one or more examples, the first wall 482 and the second wall 484 are at least approximately parallel to each other. In one or more examples, selected truss members in the truss members 424 of the truss structure 414 are omitted and replaced with the first wall 482 and the second wall 484 of the duct 480. The duct 480 is shown as having a rectangular cross-section, but can have any suitable cross-sectional shape, thereby allowing printing without auxiliary supports.

[0189] In one or more examples, first wall 482 and / or second wall 484 are approximately 0.02 inches (0.05 centimeters) thick. In one or more examples, first wall 482 and second wall 484 are spaced apart from one another (e.g., the width of hollow interior 486 is approximately 0.04 inches (0.1 centimeters)). However, other suitable sizes and / or geometries may be used for conduit 480, first wall 482, second wall 484, and / or hollow interior 486.

[0190] In one or more examples, the conduit 480 is configured to receive, contain, convey, or otherwise direct a coolant through the interior of the panel 400. As such, the coolant contacts or is otherwise in thermal communication with a portion of both the first skin 410 and the second skin 412 for heat transfer through the thickness of the panel 400 and for heat transfer through each of the first skin 410 and the second skin 412.

[0191] The conduits 480 can have any two-dimensional shape or pattern. In one or more examples, one or more conduits 480 can be connected to one or more other conduits 480 or otherwise be in fluid communication with one or more other conduits 480. In one or more examples, the conduits 480 extend from a first opening 487 to a second opening 488. Fig.29 The example of the duct 480 shown in has an illustrative pattern including multiple turns or paths. In some examples, the duct 480 can include a single continuous path, a dead end portion, a change in size, and / or any desired features. In the example shown, the openings 487, 488 are provided along the side or edge portions of the panel 400. In one or more examples, the openings 487, 488 of the duct 480 terminate at a fluid guiding manifold (not shown) coupled to the panel 400. In some examples, the panel 400 may also include additional structures and / or features configured to allow a fluid (e.g., coolant) management system to be connected to the duct 480.

[0192] In one or more examples, the duct 480 is located or disposed between the skin regions 498 of the first skin 410 and the second skin 412. In one or more examples, the duct 480 is located or disposed between the grid regions 490 of the first skin 410 and the second skin 412. In one or more examples, the duct 480 is located or disposed between the grid regions 490 of the first skin 410 and the skin regions 498 of the second skin 412. In one or more examples, a first portion of the duct 480 is located or disposed between the grid regions 490 of the first skin 410 and the second skin 412, and a second portion of the duct 480 is located or disposed between the skin regions 498 of the first skin 410 and the second skin 412. In one or more examples, the duct 480 is disposed between the skins 410, 412 in addition to any grid regions 490. In one or more examples, the duct 480 is routed around or along the grid regions 490.

[0193] In one or more examples, the conduit 480 can be configured according to the intended function of the conduit 480. For example, the conduit 480 can be configured to facilitate active cooling of equipment mounted adjacent to the panel 400. In such an example, the conduit 480 can be configured to allow smooth flow of a selected coolant fluid and provide substantial exposure of the fluid to areas of the adjacent equipment of the panel 400 by including a plurality of returns and / or parallel branches. For another example, the conduit 480 can be configured to allow fuel or lubricant to be delivered through the panel 400. In such an example, the conduit 480 can be configured to allow the fluid to flow quickly through the panel in a simple and direct path.

[0194] E. Illustrative Methods for Additive Manufacturing

[0195] refer to Fig.24 and Fig.25 , which describes the steps of an illustrative method for additive manufacturing of a workpiece ( Fig.24 ). Exemplary additive manufacturing apparatus ( Fig.25 ) can be used in the following method steps. Where appropriate, reference can be made to components and systems that can be used to perform each step. These references are for illustration and are not intended to limit the possible ways to perform any particular step of the method.

[0196] refer to Fig.24 , which shows a flow chart of steps performed in an example of an additive manufacturing method (referred to herein as method 500). It should be understood that Fig.24 The flowchart shown may not describe the entire process or all steps of method 500. Although the various steps of method 500 are described below and in Fig.24Although shown in the flowchart, these steps do not necessarily have to be performed in their entirety and in some cases may be performed simultaneously or in an order different from that shown.

[0197] In one or more examples, at step 510, digital information describing a plurality of ordered layers is received. The digital information may be provided by, for example, Fig.25 The computer controller 612 of the additive manufacturing device 610 shown receives the digital design information. The additive manufacturing device 610 may also be referred to as a printer 610 or a manufacturing machine. The computer controller 612 may include any data processing system configured to receive digital design information and control the functions of the printer 610. Fig.25 The exemplary computer controller shown includes a processor 614 for controlling printer functions and a memory 616 for storing received data.

[0198] The received information may include geometric data and / or design details of a plurality of two-dimensional patterns of layers that make up a three-dimensional object, wherein the three-dimensional object is a workpiece 628 to be manufactured, such as a truss panel (e.g., panels 100, 200, 300, 400). The layers may also be described as cross-sections or slices. The plurality of layers are ordered such that the layers may be numbered or organized from the first layer to the last layer.

[0199] In one or more examples, step 512 of method 500 includes depositing raw material on a build platform 618 located in a build environment 620 of printer 610. Build platform 618 can include a support that can be moved along a manufacturing axis 622 by computer controller 612. Build platform 618 can have a flat surface that is perpendicular to manufacturing axis 622.

[0200] The raw material can be any material suitable for additive manufacturing, typically a fluid, filament, sheet, binder suspension or powder. The raw material can include polymers, plaster, ceramics, metals or composites. The polymer raw material may include thermoplastics (e.g., polyvinyl alcohol (PVA), polydimethylsiloxane (PDMS), polyetherketoneketone (PEKK), polylactic acid (PLA), nylon, acrylonitrile butadiene styrene (ABS) plastic, polycarbonate (PC), polyetherimide (PEI), polyimide (PI), polystyrene (PS), polytetrafluoroethylene (PTFE), acrylics (e.g., poly(methyl methacrylate), polypropylene (PP), polyethylene (PE)), thermosetting plastics (e.g., photopolymer resins, epoxy resins), hydrogels, or any combination thereof. The metal may include any high-strength, high-temperature metal or metal alloy, such as aluminum and its alloys, titanium and its alloys, niobium and its alloys, chromium-nickel-inconel alloys, or any combination thereof. The material may be dispensed from a raw material source 624 (e.g., a hopper, a tank, or a powder bed). For example, aluminum powder may be swept from a powder bed onto a build platform 618 by a brush arm actuated by a computer controller 612.

[0201] The raw material may be evenly distributed on the building platform 618 or may be deposited in a selected pattern. The deposition may be performed under the control of the computer controller 612. In some examples, the building platform 618 may be immersed in the raw material, and the deposition may be accomplished by gravity or fluid pressure. In some examples, a print head 626 connected to a raw material source 624 may deposit the raw material in a pattern corresponding to a first layer of the ordered plurality of layers.

[0202] In one or more examples, the raw material is altered to produce a first layer at step 514. In other words, a physical change is induced in the deposited material according to the design information describing the first layer of the ordered plurality of layers and as directed by computer controller 612 to realize the first layer as a physical object on build platform 618.

[0203] The material may be acted upon by a print head 626 of the printer 610, which is controlled by the computer controller 612. For example, the print head 626 may include a laser that cures a photopolymer by exposure to light or sinters a metal powder by exposure to heat. The print head 626 may be directed by the computer controller 612 to follow a path depicted in the received digital information for the first layer, and / or a path calculated by the processor 614 based on the received digital information.

[0204] In one or more examples, step 516 includes repositioning build platform 618. In some examples, build platform 618 can be positioned a selected distance from print head 626. The selected distance can be determined by a process performed by print head 626. After generating a layer, build platform 618 can be repositioned by computer controller 612, i.e., away from print head 626 along manufacturing axis 622 by the thickness of the layer. That is, build platform 618 can be moved so that the top surface of the generated layer is a selected distance from print head 626.

[0205] In some examples, build platform 618 can be aligned with another element of printer 610 (e.g., a raw material dispensing component). After generating a layer, build platform 618 can be repositioned by computer controller 612 along manufacturing axis 622 so that the top surface of the generated layer is aligned with other elements of printer 610. In some examples, at step 516, print head 626 can be repositioned instead of or in addition to build platform 618. In some examples, step 516 can be skipped.

[0206] In one or more examples, at step 518, a raw material is deposited on the layer produced in the previous step of method 500. As described in step 512, the raw material can be any suitable material and can be deposited in any suitable manner. At step 520, the raw material is altered to produce the next layer, as previously described for step 514.

[0207] In one or more examples, steps 516 to 520 may be repeated to generate each of the multiple layers of the received digital information until the last layer is generated. The first to last layers generated may then form workpiece 628 as described in the received digital information. Workpiece 628 may be removed from printer 610 and post-processed as desired. For example, workpiece 628 may be machined from a build plate of build platform 618, and fine details or a smooth surface may then be further finished by machining or other methods.

[0208] F. Exemplary Methods for Additive Manufacturing Aerospace Panels

[0209] See also Fig.26 , this section describes steps of an illustrative method (referred to herein as method 700) for additively manufacturing an aerospace panel (e.g., panels 100, 200, 300, 400). Aspects of the panels and / or methods described above may be used and / or referenced in the method steps described below. Where appropriate, reference may be made to components and systems that may be used to perform each step. These references are for illustration and are not intended to limit possible ways of performing any particular step of the method.

[0210] Fig.26 700 is a flowchart showing the steps performed in an example of method 700, and may not describe the entire process or all steps of method 700. Although the individual steps of method 700 are described below and in Fig.26 Although shown in the flowchart, these steps do not necessarily have to be performed in their entirety and in some cases may be performed simultaneously or in an order different from that shown.

[0211] At step 710, the method includes printing a first skin (e.g., first skin 110, 210, 310, 410) and a second skin (e.g., second skin 112, 212, 312, 412). The skins may also be described as surface panels and / or face walls. These skins may be printed according to any effective additive manufacturing method, such as those described above and in Fig.24 The method 500 is shown in FIG. The skin may be printed from any material including, but not limited to, thermoplastics, thermosets, ceramics, and laser sintered metals or metal alloys.

[0212] In one or more examples, the first skin can be spaced apart from the second skin and can be parallel to the second skin. In one or more examples, the first skin and the second skin are non-parallel. In some examples of method 700, the skins can be joined at a common edge. Each skin can have a generally flat extent and a limited thickness. The thickness of the skins can be equal, can be different and / or can vary across the skin. The skins can be printed according to a build direction of the additive manufacturing equipment used. Each skin can have an inner side and an outer side, wherein each inner side and outer side extend parallel to the build direction during printing. Step 710 can also be described as printing the skins vertically, and / or the skins can be described as being parallel to the build direction during printing.

[0213] In one or more examples, step 712 of the method includes printing a connecting truss (e.g., truss structure 114, truss structure 214, truss structure 314, truss structure 414). The truss can be connected to the first skin and can be connected to the second skin, thereby connecting the first skin to the second skin. The truss can be described as being sandwiched between the first skin and the second skin and / or as forming a core of a panel including the first skin and the second skin.

[0214] In one or more examples, the truss includes a plurality of elongated and / or cross-shaped members (e.g., truss member 118, truss member 224, truss member 324, truss member 424) arranged in an array of core structures. Each core structure may include a geometric frame, such as a pyramid frame or a cubic frame. The plurality of elongated truss members may be arranged such that the truss members serve as structural trusses and transfer loads between the first skin and the second skin. Each member may be constructed and / or oriented such that the truss can be printed without auxiliary supports. That is, the truss may be printable without the need for subsequent removal of sacrificial support structures.

[0215] In one or more examples, the truss is printed simultaneously with the first skin and the second skin. That is, steps 710 and 712 can be performed simultaneously. Each layer of material deposited during printing can include a portion of the first skin, a portion of the truss, and a portion of the second skin. The first skin, the second skin, and the truss can be printed as a single, integral structure. That is, the skin and the truss can be printed together to form a panel formed of printed material without joints or seams.

[0216] In one or more examples, at step 714, method 700 includes printing an integrated feature of the panel. Fig.26Some illustrative optional features are shown in FIG. 714 , but any suitable structural and / or functional features may be printed as part of step 714. Each of step 714 and sub-steps 716 to 725 may be performed at least partially concurrently with steps 710 and 712. That is, during some duration of printing of the first skin, the second skin, and the truss structure, integrated features may be printed concurrently. All printed features may be printed as part of the overall structure of the panel. All printed features may be configured to be printed without auxiliary supports.

[0217] In one or more examples, sub-step 716 includes printing a channel (e.g., channel 474) inside the first skin. The first skin can be printed with an increased thickness to allow integration of the channel. Alternatively or additionally, the channel can be integrated or embedded in the second skin and / or integrated or embedded between the first skin and the second skin. The channel can have any suitable cross-sectional shape and / or path and can be configured according to the intended function of the channel. For example, the channel can be configured to facilitate heating or cooling of equipment mounted adjacent to the panel.

[0218] In one or more examples, sub-step 718 includes printing a passage through the panel (e.g., access hole 466 and / or hole 470). The passage can extend from the outside of the first skin through the panel to the outside of the second skin. The passage can be defined by a tubular wall (e.g., wall 468 or wall 472). For example, the passage can have a circular cross-sectional shape and can be defined by a cylindrical wall. The wall can be disposed between the first skin and the second skin and can extend through a gap in the truss.

[0219] In one or more examples, sub-step 720 includes printing a third skin (e.g., third skin 450) and a second truss (e.g., second truss structure 452). The second truss can be substantially the same as the truss printed in step 712, or can have any desired geometry and / or include any suitable core frame. The relative alignment of the core frames of the two trusses can be selected to provide desired structural reinforcement or other structural interaction. The third skin can be parallel to the second skin but spaced apart. The first skin, the second skin, and the third skin can match in shape and / or thickness. The third skin can be connected to the second skin via the second truss. The second skin can be sandwiched between the second truss and the truss printed in step 712. The first skin and the third skin can form the outer surface of the panel.

[0220] In one or more examples, sub-step 722 includes printing a thickened portion (e.g., reinforced area 457) of the first skin and / or the second skin. The thickened portion can be rectangular, circular, shaped to conform to a structure adjacent to the panel after the panels are assembled into a structure, and / or any suitable shape. The increased thickness can extend inward relative to the skin so that the outer surface of the skin is not affected by the thickening. At the outer boundary of the thickened portion, the skin may include a radius, a chamfer, or other shape that is configured to provide a gradual transition between the increased thickness and the rest of the skin. In some examples, sub-step 722 may include printing multiple thickened portions on the first skin and / or printing one or more thickened portions on the second skin. The thickened portion may include a solid skin area of ​​the skin, a lattice area of ​​the skin, or at least a portion of both.

[0221] In one or more examples, sub-step 724 includes printing non-planar reinforcements, such as skin reinforcements extending from a skin region of the skin (e.g., skin reinforcement 132, skin reinforcement 262, skin reinforcement 368). The non-planar skin reinforcements can be triangular reinforcements. The skin reinforcements can be printed on the inside and / or outside of the skin region of the first skin and / or the second skin. The skin reinforcements can include elongated local thickenings of the skin and can be arranged in any suitable pattern. For example, the skin reinforcements can form a grid and / or lattice pattern. The skin reinforcements can be positioned to coincide with the nodes of the truss to facilitate connection of the truss members to the first skin and / or the second skin.

[0222] In some examples, sub-step 724 includes the steps of printing a first mesh of the reinforcement with the first skin and printing a second mesh of the reinforcement with the second skin. In some examples, the steps of printing the first mesh of the reinforcement and printing the second mesh of the reinforcement include the steps of printing the first mesh of the reinforcement to form one or more first mesh squares and printing the second mesh of the reinforcement to form one or more second mesh squares, respectively. The first mesh squares are offset from the second mesh squares so that each of the first nodes is aligned with a geometric center of one of the second mesh squares when the panel is viewed in a direction orthogonal to the first skin.

[0223] In one or more examples, sub-step 725 includes printing at least one grid region (e.g., grid region 120, grid region 250, grid region 350, grid region 490) defining a grid (e.g., grid 128, grid 251, grid 351, grid 491) in at least one of the first skin and the second skin, the grid being configured to eliminate auxiliary printing supports, including a grid of grid members and an array of openings. In some examples, the step of printing one or more grid regions includes the step of printing a grid of grid reinforcements (e.g., grid reinforcements 136, grid reinforcements 260, grid reinforcements 360, grid reinforcements 496) with the grid. In some examples, the grid formed by the grid members and grid reinforcements forms a grid grid square, which can correspond to one or more first grid squares or one or more second grid squares of the skin in which the grid formed by the grid reinforcements is located.

[0224] In one or more examples, sub-step 726 includes printing walls (e.g., upper wall 460, lower wall 462, and side wall 464) along the edges of the panel. The walls can extend between the first skin and the second skin, and can extend perpendicular to the two skins. The walls can be constructed according to the orientation of the wall relative to the build direction or build axis of the additive manufacturing method used in printing the wall, so that the walls can be printed without auxiliary supports. For example, the walls extending parallel to the build axis can be substantially planar. For another example, the walls extending perpendicular to the build axis can have planar and angled and / or inverted V-shaped faces. In some examples, sub-step 726 can include printing additional walls along other edges of the panel and / or printing walls along each edge of the panel.

[0225] In one or more examples, step 728 includes connecting a panel to another panel. The panels can be connected along edges or side regions, and can be connected in a plane or at an angle relative to another panel. The panels can be connected in any effective manner. For example, the panels can be welded and / or bolted to adjacent panels.

[0226] In one or more examples, the method 700 may not include post-processing of the panel. That is, the panel may be designed and printed such that smoothing of surface roughness, removal of sacrificial support material, and / or machining of additional features is not required.

[0227] G. Illustrative Examples of Aerospace Vehicles

[0228] See also Figures 1A to 1DIn one or more examples, an aerospace vehicle 102 includes a body 104. The body 104 includes one or more panels 100. Each panel 100 includes a first skin 110 and a second skin 112 spaced apart from the first skin 110. Each panel 100 also includes a truss structure 114. The truss structure 114 connects the first skin 110 and the second skin 112. The truss structure 114 includes a plurality of truss members 118. Each truss member 118 is integral with the first skin 110 and the second skin 112, such that the first skin 110, the second skin 112, and the truss structure 114 together form a single, unitary, jointless structure. In one or more examples, at least one of the first skin 110 and the second skin 112 includes at least one grid region 120. In Figures 1B to 1D In the example shown, the first skin 110 and the second skin 112 each include at least one grid region 120. The at least one grid region 120 defines or takes the form of a grid 128 (e.g., a grid structure) configured to eliminate auxiliary printing supports. The grid 128 of the at least one grid region 120 includes a grid of grid members 122 and an array of openings 124. In one or more examples, at least one of the first skin 110 and the second skin 112 also includes at least one skin region 126.

[0229] H. Illustrative Implementation of Aerospace Panels

[0230] See now Fig. 27 and Fig.28 The examples of panels 100, 200, 300, 400 and method 700 described herein may be related to or in the context of a manufacturing and repair method 1100 (e.g. Fig. 27 ) and aerospace vehicle 1200 (as shown in the flowchart of Fig.28 As an example, the aerospace vehicle 1200 and / or the manufacturing and repair method 1100 may include one or more additively manufactured aerospace truss panels, such as the panels 100, 200, 300, 400 manufactured according to the method 700.

[0231] See also Fig.28 , which shows an example of an aerospace vehicle 1200. The aerospace vehicle 1200 is an example of the aerospace vehicle 102 ( Figures 1A to 1D). In one or more examples, aerospace vehicle 1200 includes one or more panels 1216. Panel 1216 is an example of panel 100, 200, 300, 400, as described and shown herein, and takes the form of an additively manufactured truss panel. Generally, aerospace vehicle 1200 includes fuselage 1202. In one or more examples, panel 1216 is mounted to fuselage 1202. In one or more examples, aerospace vehicle 1200 includes interior 1206. Aerospace vehicle includes multiple onboard systems 1204 (e.g., advanced systems). Examples of onboard systems 1204 of aerospace vehicle 1200 include propulsion system 1208, hydraulic system 1212, electrical system 1210, and environmental system 1214. In other examples, onboard systems 1204 also include one or more control systems. In other examples, onboard systems 1204 also include one or more other systems, such as, but not limited to, communication systems, avionics systems, software distribution systems, network communication systems, passenger information / entertainment systems, guidance systems, radar systems, weapon systems, etc.

[0232] See also Fig. 27 During pre-production of the aerospace vehicle 1200, the manufacturing and service method 1100 includes specification and design of the aerospace vehicle 1200 (block 1102) and material procurement (block 1104). During production of the aerospace vehicle 1200, component and subassembly manufacturing (block 1106) and system integration (block 1108) of the aerospace vehicle 1200 is performed. Thereafter, the aerospace vehicle 1200 is certified and delivered (block 1110) to be placed in service (block 1112). Routine maintenance and repair (block 1114) includes modification, reconfiguration, refurbishment, etc. of one or more systems of the aerospace vehicle 1200.

[0233] Fig. 27 Each process of the manufacturing and maintenance method 1100 shown can be performed or implemented by a system integrator, a third party and / or an operator (e.g., a customer). For the purpose of this specification, a system integrator may include, but is not limited to, any number of spacecraft manufacturers and main system subcontractors; a third party may include, but is not limited to, any number of sellers, subcontractors, and suppliers; an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0234] Examples of panels 100, 200, 300, 400 and methods 700 shown and described herein may be found in Fig. 27The method 700 may be used during any one or more of the stages of the manufacturing and repair method 1100 shown in the flowchart. In one example, the installation and use of the panel 100, 200, 300, 400 and / or the manufacture of the panel 100, 200, 300, 400 according to the method 700 may form part of component and subassembly manufacturing (block 1106) and / or system integration (block 1108). In addition, the installation and use of the panel 100, 200, 300, 400 and / or the manufacture of the panel 100, 200, 300, 400 according to the method 700 may be performed in a manner similar to components or subassemblies prepared while the aerospace vehicle 1200 is in service (block 1112). Additionally, the installation and use of the panels 100, 200, 300, 400 and / or the manufacture of the panels 100, 200, 300, 400 according to the method 700 may be used during system integration (block 1108) and certification and delivery (block 1110). Similarly, the installation and use of the panels 100, 200, 300, 400 and / or the manufacture of the panels 100, 200, 300, 400 according to the method 700 may be used, for example but not limited to, while the aerospace vehicle 1200 is in service (block 1112) and during maintenance and repair (block 1114).

[0235] Illustrative combinations and additional examples

[0236] This section describes additional aspects and features of exemplary additively manufactured truss panels, which are presented as, but not limited to, a series of paragraphs, some or all of which may be alphanumeric for clarity and efficiency. Each of these paragraphs may be combined in any suitable manner with one or more other paragraphs and / or disclosure elsewhere in this application. Some of the following paragraphs explicitly reference and further qualify other paragraphs, thereby providing non-limiting examples of some suitable combinations.

[0237] Item A0. An additively manufactured (e.g., 3D printed) panel for aerospace, the panel comprising: a first skin; a second skin spaced apart from the first skin; and a first truss structure connecting the first skin to the second skin, the first truss structure comprising a plurality of truss members, and each truss member is integral with the first skin and the second skin, so that the first skin, the second skin and the first truss structure together form a single integral jointless structure; wherein at least one of the first skin and the second skin comprises at least one grid region, the at least one grid region defining a grid configured to eliminate auxiliary printing supports, the at least one grid region comprising a grid grid and an array formed by openings.

[0238] Clause A1. An aerospace panel as described in Clause A0, wherein the first skin includes a first grid formed by skin reinforcements; the second skin includes a second grid formed by skin reinforcements; and each truss member extends between a first node and a second node, the first node being defined at the intersection of the first grid formed by the reinforcements and the second node being defined at the intersection of the second grid formed by the reinforcements.

[0239] Clause A2. The aerospace panel of Clause A0 or A1, wherein, in the one or more grid regions, the grid mesh further comprises one or more grids formed by grid stiffeners.

[0240] Clause A3. The aerospace panel of any of Clauses A0 to A2, wherein the first skin and the second skin are parallel.

[0241] Clause A4. The aerospace panel of any of Clauses A0 to A2, wherein the first skin and the second skin are non-parallel.

[0242] Clause A5. The aerospace panel of any of Clauses A0 to A4, wherein the first skin and the second skin share a common edge.

[0243] Clause A6. The aerospace panel of any of Clauses A0 to A5, wherein both the first skin and the second skin have at least one grid region.

[0244] Clause A7. An aerospace panel as described in any of Clauses A0 to A6, wherein both the first skin and the second skin have at least one grid region, and the grid regions differ from each other in size and / or position on their respective skins.

[0245] Clause A8. An aerospace panel of any of clauses A0 to A7, wherein: the first grid formed by the reinforcement defines one or more first grid squares; the second grid formed by the reinforcement defines one or more second grid squares; the first grid squares are offset from the second grid squares so that when the aerospace panel is viewed in a direction orthogonal to the first skin, each of a plurality of first nodes is aligned with a geometric center of one of the second grid squares; and the one or more grids formed by the lattice reinforcement define one or more lattice grid squares, the one or more lattice grid squares corresponding to the one or more first grid squares or the one or more second grid squares of the skin in which the grid formed by the lattice reinforcement is located.

[0246] Clause A9. The aerospace panel of any of Clauses A1 to A8, wherein at least one of the first grid formed by the skin reinforcement and the second grid formed by the skin reinforcement is non-planar.

[0247] Clause A10. The aerospace panel of any of Clauses A2 to A9, wherein at least one or more grids formed by the lattice stiffener are non-planar.

[0248] Clause A11. An aerospace panel as described in any of Clauses A0 to A10, further comprising a wall extending between the first skin and the second skin along at least one edge of the aerospace panel; wherein the first skin, the second skin, the first truss structure and the wall together form the single integral jointless structure.

[0249] Clause A12. An aerospace panel as described in any of Clauses A0 to A11, wherein: the plurality of truss members include a plurality of X-shaped truss members; and each X-shaped truss member extends between a pair of first nodes on the first skin and a pair of second nodes on the second skin.

[0250] Clause A13. The aerospace panel of any of Clauses A0 to A12, wherein: the plurality of truss members form an array formed by a core structure; and a density of the core structure varies over at least one region of the aerospace panel.

[0251] Clause A14. An aerospace panel as described in any of Clauses A0 to A13, comprising: a third skin, which is spaced apart from the second skin; and a second truss structure, which connects the second skin to the third skin; wherein the first skin, the second skin, the third skin, the first truss structure and the second truss structure together form the single integral jointless structure.

[0252] Item A15. An aerospace panel of any one of Items A0 to A14, wherein: the aerospace panel has: a primary axis parallel to the longitudinal direction of the first skin and the second skin; and a secondary axis perpendicular to the primary axis and orthogonal to the first skin and the second skin; when the aerospace panel is observed along a direction perpendicular to both the primary axis and the secondary axis, each truss member is oriented at a first truss angle of approximately 35 to 50 degrees relative to the secondary axis; and when the aerospace panel is observed along the primary axis, each truss member is oriented at a second truss angle of approximately 35 to 50 degrees relative to the secondary axis.

[0253] Clause A16. The aerospace panel of any of Clauses A0 to A15, wherein at least one of the first skin and the second skin has an internal channel embedded in the first skin and / or the second skin, respectively.

[0254] Clause A17. The aerospace panel of any of Clauses A0 to A16, wherein the panel is comprised of a polymer, gypsum, ceramic, metal, or a composite material.

[0255] Clause A18. An aerospace panel as described in any of Clauses A0 to A16, wherein the panel is composed of a metal or metal alloy, such as aluminum and its alloys, titanium and its alloys, niobium and its alloys, Inconel, or any combination thereof.

[0256] Item B0. An aerospace vehicle, comprising: a body having one or more aerospace panels, each aerospace panel comprising: a first skin; a second skin, the second skin being spaced apart from the first skin; and a first truss structure, the first truss structure connecting the first skin to the second skin, the first truss structure comprising a plurality of truss members, and each truss member being integral with the first skin and the second skin, so that the first skin, the second skin and the first truss structure together form a single integral jointless structure; wherein at least one of the first skin and the second skin comprises at least one grid region, the at least one grid region defining a grid configured to eliminate auxiliary printing supports, the at least one grid region comprising a grid formed by grid reinforcements and an array formed by openings.

[0257] Clause B1. The aerospace vehicle of clause B0, wherein the aerospace vehicle is a satellite.

[0258] Item C0. A method for manufacturing an aerospace panel, the method comprising: printing a first skin and a second skin spaced apart from the first skin, and simultaneously printing a plurality of truss members of a first truss structure connecting the first skin to the second skin, thereby obtaining a single integral jointless structure; wherein at least one of the first skin and the second skin includes at least one grid area, the at least one grid area defining a grid configured to eliminate auxiliary printing supports, the at least one grid area including a grid formed by the grid and an array formed by openings.

[0259] Item C1. A method as described in Item C0, wherein the steps of printing the first skin and printing the second skin respectively include printing a first grid formed by reinforcements together with the first skin, printing a second grid formed by reinforcements together with the second skin, and printing one or more grids formed by grid reinforcements in at least one of the grid areas; and printing the multiple truss members includes printing each truss member to extend between a first node and a second node, the first node being defined at the intersection of the first grid formed by reinforcements, and the second node being defined at the intersection of the second grid formed by reinforcements, wherein, in the one or more grid areas, the grid grid includes one or more grids formed by grid reinforcements.

[0260] Clause C2. A method as described in clause C0 or C1, wherein printing a first grid formed by a reinforcement and printing the second grid formed by a reinforcement respectively include: printing the first grid formed by the reinforcement to form one or more first grid squares; printing the second grid formed by the reinforcement to form one or more second grid squares; wherein the first grid square is offset from the second grid square so that when the aerospace panel is observed in a direction perpendicular to the first skin, each first node is aligned with the geometric center of one of the second grid squares; and wherein the one or more grids formed by the lattice reinforcement form one or more lattice grid squares, and the one or more lattice grid squares correspond to the one or more first grid squares or the one or more second grid squares of the skin where the grid formed by the lattice reinforcement is located.

[0261] Item C3. The method of any one of Items C0 to C2, further comprising: printing a wall while printing the first skin, the second skin, and the first truss structure; the wall extending between the first skin and the second skin along at least one edge of the aerospace panel.

[0262] Clause C4. The method of any one of clauses C0 to C3, wherein printing the plurality of truss members comprises printing a plurality of X-shaped truss members, each X-shaped truss member extending between a pair of first nodes on the first skin and a pair of second nodes on the second skin.

[0263] Clause C5. The method of any one of clauses C0 to C4, wherein printing the plurality of truss members comprises printing the plurality of truss members as an array formed of a core structure having a density that varies over at least one region of the aerospace panel.

[0264] Clause C6. The method as described in any one of clauses C0 to C5, further comprising: while printing the first skin, the second skin, and the first truss structure, printing a third skin spaced apart from the second skin and a second truss structure connecting the second skin to the third skin.

[0265] Item C7. A method as described in any one of Items C0 to C6, wherein: the aerospace panel has: a primary axis, which is parallel to the longitudinal direction of the first skin and the second skin; and a secondary axis, which is perpendicular to the primary axis and orthogonal to the first skin and the second skin; and the step of printing the multiple truss members includes: printing each truss member at a first truss angle of approximately 35 to 50 degrees relative to the secondary axis when the aerospace panel is observed along a direction perpendicular to both the primary axis and the secondary axis and at a second truss angle of approximately 35 to 50 degrees relative to the secondary axis when the aerospace panel is observed along the primary axis.

[0266] Clause C8. The method of any one of clauses C0 to C7, wherein printing the first skin and the second skin comprises printing at least one of the first skin and the second skin such that an internal channel is embedded in the first skin and / or the second skin.

[0267] Item C9. A method as described in any one of Items C0 to C8, wherein printing the first skin, the second skin and the first truss structure includes: using an additive manufacturing device to print the aerospace panel so that the longitudinal direction of the first skin and the second skin is parallel to the building direction of the additive manufacturing device.

[0268] Clause C10. The method of any of clauses C0 to C9, wherein the printing material comprises a polymer, plaster, ceramic, metal, or a composite material.

[0269] Clause C11. A method as described in any of clauses C0 to C9, wherein the printing material comprises a metal or a metal alloy, such as aluminum and its alloys, titanium and its alloys, niobium and its alloys, Inconel, or any combination thereof.

[0270] Advantages, Features and Benefits

[0271] The various examples of additively manufactured truss panels described herein provide several advantages over known solutions for manufacturing aerospace panels. For example, the illustrative examples described herein allow for rapid, on-demand production of such panels.

[0272] Additionally, the illustrative examples described herein reduce manufacturing cycle time, including reducing the number of manufacturing steps, hard labor time, and post-production testing, among other benefits.

[0273] Additionally, the illustrative examples described herein improve thermal performance and heat removal by removing impedance between the skin and core structure from the adhesive material, among other benefits.

[0274] Additionally, the illustrative examples described herein allow structural features such as mounting points, stiffeners, and / or heat pipes to be integrated and manufactured as part of the panel, among other benefits.

[0275] Additionally, the illustrative examples described herein allow for a high level of customization and localized design including features such as localized reinforcement or radiation point shielding, access points, stiffness tuning, customization for heat spreading and heat dissipation, and thickening at weld joints to accommodate strength losses in heat affected zones, among other benefits.

[0276] Additionally, the illustrative examples described herein allow for increased levels of customization and localized design including features such as localized customized grids for material reduction, stiffness tuning, and customization for heat spreading and heat dissipation, among other benefits.

[0277] Additionally, the illustrative examples described herein provide important applications for aircraft avionics cooling racks and other aircraft structures, among other benefits.

[0278] Additionally, the illustrative examples described herein enable tailoring of a panel's through-panel thermal conductivity for thermal management by varying (eg, increasing or decreasing) the density of the panel's truss structure, among other benefits.

[0279] Additionally, the exemplary examples described herein enable the panels to be lighter than comparable composite sandwich panels having solid skins by tailoring the design of each of the panel's skins to include at least one lattice skin region, at least one solid skin region, and any combination thereof, among other benefits.

[0280] Additionally, among other benefits, the illustrative examples described herein improve upon conventional sandwich panels by enabling additively manufactured micro-truss panels with a lattice skin. The lattice skin can be additively manufactured (e.g., 3D printed) with minimal thickness, but with significant additional mass reduction by completely eliminating material of the skin where it is not needed using the lattice structure. With less skin mass, the lattice skin panels can be additively manufactured faster due to reduced metal deposition, and thus support an accelerated production system and lower machine time and machine time costs. The lattice structure of the skin can be populated where needed to use equipment mounting, integral thermal multipliers, structural uses, radiation shielding, etc., or a combination thereof.

[0281] There are no known systems or devices that can perform these functions, particularly for high strength and lightweight metal alloy panels. Therefore, the illustrative examples described herein are particularly useful for aerospace vehicle structural panels. However, not all examples described herein provide the same advantages or the same degree of advantages.

[0282] in conclusion

[0283] The above disclosure may include multiple different examples with independent utility. Although each of these has been disclosed in its preferred form, the specific examples disclosed and described herein should not be considered restrictive, because many variations are possible. With respect to the section titles used in this disclosure, such titles are used only for organizational purposes. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various elements, features, functions and / or properties disclosed herein. The following claims specifically point out certain combinations and sub-combinations that are considered novel and non-obvious. Other combinations and sub-combinations of features, functions, elements and / or properties may be claimed in applications claiming priority to this application or a related application. Such claims, whether broader, narrower, equal or different in scope than the original claims, are also considered to be included in the subject matter of the present disclosure.

[0284] As used herein, the system, equipment, device, structure, article, element, component or hardware that is "configured to" perform a specified function is actually able to perform the specified function without any change, rather than just having the potential to perform the specified function after further modification. In other words, for the purpose of performing the specified function, the system, equipment, device, structure, article, element, component or hardware that is "configured to" perform the specified function is specially selected, created, realized, utilized, programmed and / or designed. As used herein, "configured to" represents the existing features of a system, equipment, structure, article, element, component or hardware, and the existing features enable the system, equipment, structure, article, element, component or hardware to perform the specified function without further modification. For the purposes of this disclosure, the system, equipment, device, structure, article, element, component or hardware that is described as "configured to" perform a specific function can be additionally or alternatively described as "suitable for" and / or described as "operating to" perform the function.

[0285] Unless otherwise indicated, the terms "first," "second," "third," etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Furthermore, reference to, for example, a "second" item does not require or preclude the presence of, for example, a "first" or lower numbered item and / or, for example, a "third" or higher numbered item.

[0286] As used herein, the phrase "at least one of...", when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one of each item in the list may be required. For example, "at least one of Item A, Item B, and Item C" may include, but is not limited to: Item A; or Item A and Item B. This example may also include: Item A, Item B, and Item C; or Item B and Item C. In other examples, "at least one of..." may be, for example, but not limited to: two of Item A, one of Item B, and ten of Item C; four of Item B and seven of Item C; and other suitable combinations. As used herein, the term "and / or" and the " / " symbol include any and all combinations of one or more of the associated listed items.

[0287] For the purposes of this disclosure, the term "connection" and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, placed in communication, or otherwise associated (e.g., mechanically, electrically, fluidically, optically, electromagnetically) with each other. In various examples, the elements may be associated directly or indirectly. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, for example, via another element C. It should be understood that it is not necessary to represent all associations between various disclosed elements. Therefore, there may also be connections different from those shown in the figure.

[0288] Unless otherwise indicated, all numbers expressing quantities and properties (e.g., lengths, weights, etc.) used in the specification and claims are to be understood as being modified in all instances by the term "about" or "approximately". Therefore, unless otherwise indicated, the numerical parameters set forth in this specification and the appended claims are approximate values ​​that may vary depending upon the desired properties sought to be obtained. At the very least, and without attempting to limit the application of the doctrine of equivalents to the scope of the claims, each numerical value should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0289] As used herein, the term "approximately" refers to or represents a condition that is close, but not exactly close, to a condition that still performs a desired function or achieves a desired result. For example, the term "approximately" refers to a condition that is within an acceptable predetermined tolerance or precision, such as a condition within 10% of the condition. However, the term "approximately" does not exclude a condition that is exactly the condition. As used herein, the term "substantially" refers to a condition that is substantially the condition that performs a desired function or achieves a desired result.

[0290] The terms "a", "an", "the" and similar referents used in the context of describing the present invention (particularly in the context of the appended claims) should be interpreted as covering both the singular and the plural, unless otherwise indicated herein or clearly contradicted by the context. The use of any and all examples or exemplary language (e.g., "such as") provided herein is intended only to better illustrate the present invention and does not limit the scope of any claim. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the present invention.

[0291] The grouping of alternative elements or embodiments disclosed herein should not be construed as limiting. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. It is expected that one or more members of the group may be included in the group or deleted from the group for convenience and / or patentability. When this inclusion or deletion occurs, the specification is considered to include the group of modification, so the written description of all Markush groups used in the appended claims is met.

[0292] Certain embodiments are described herein, including the best mode known to the inventor for carrying out the invention. Of course, after reading the foregoing description, variations of the described embodiments will be apparent to those of ordinary skill in the art. Those skilled in the art expect to adopt such variations appropriately, and the disclosed examples are intended to be practiced in a manner different from that specifically described herein. Therefore, as permitted by applicable law, the claims include all modifications and equivalents of the subject matter described in the claims. In addition, unless otherwise specified herein or clearly contradictory to the context, any combination of the above elements in all possible variations thereof is contemplated.

[0293] It should be understood that the embodiments disclosed herein are illustrative of the principles of the claims. Other modifications that may be employed are within the scope of the claims. Therefore, by way of example and not limitation, alternative embodiments may be used in accordance with the teachings herein. Therefore, the claims are not limited to the embodiments precisely shown and described.

Claims

1. An aerospace panel (100, 200, 300, 400), the aerospace panel comprising: First skin (110, 210, 310, 410); a second skin (112, 212, 312, 412) spaced apart from the first skin (110, 210, 310, 410); as well as A truss structure (114, 214, 314, 414) connects the first skin (110, 210, 310, 410) to the second skin (112, 212, 312, 412), the truss structure (114, 214, 314, 414) comprising a plurality of truss members (118, 224, 324, 424), and each truss member (118, 224, 324, 424) 4, 424) is integral with the first skin (110, 210, 310, 410) and the second skin (112, 212, 312, 412), so that the first skin (110, 210, 310, 410), the second skin (112, 212, 312, 412) and the truss structure (114, 214, 314, 414) together form a single integral jointless structure, in: At least one of the first skin (110, 210, 310, 410) and the second skin (112, 212, 312, 412) includes at least one grid region (120, 250, 350, 490) defining a grid (128, 251, 351, 491) configured to eliminate auxiliary printing supports; and The at least one grid region (120, 250, 350, 490) includes a grid mesh (128, 251, 351, 491) and an array of openings (124, 252, 352, 492).

2. The aerospace panel (100, 200, 300, 400) of claim 1, wherein: The first skin (110, 210, 310, 410) has a first grid formed by reinforcement members (132, 262, 368); The second skin (112, 212, 312, 412) has a second grid formed by reinforcement members (132, 262, 368); Each truss member (118, 224, 324, 424) extends between a first node (134, 258, 358, 497) defined at an intersection of the first grid formed by the reinforcement members (132, 262, 368) and a second node (134, 258, 358, 497) defined at an intersection of the second grid formed by the reinforcement members (132, 262, 368); and In the at least one grid region (120, 250, 350, 490), the grid mesh (128, 251, 351, 491) includes one or more grids formed by grid reinforcements (136, 260, 360, 496).

3. The aerospace panel (100, 200, 300, 400) of claim 2, wherein: The first grid formed by the reinforcement members (132, 262, 368) defines one or more first grid squares (246); The second grid formed by the reinforcement members (132, 262, 368) defines one or more second grid squares (246); The first grid square (246) is offset from the second grid square (246) such that each first node (134, 258, 358, 497) is aligned with a geometric center of one of the second grid squares (246) when the aerospace panel (100, 200, 300, 400) is viewed in a direction normal to the first skin (110, 210, 310, 410); and The one or more grids formed by the grid stiffeners (136, 260, 360, 496) define one or more grid grid squares corresponding to the one or more first grid squares (246) or the one or more second grid squares (246) of the skin in which the grid formed by the grid stiffeners (136, 260, 360, 496) is located.

4. The aerospace panel (100, 200, 300, 400) according to claim 2, wherein: At least one of the first grid formed by skin reinforcements (132, 262, 368) and the second grid formed by skin reinforcements (132, 262, 368) is non-planar.

5. The aerospace panel (100, 200, 300, 400) of claim 1, further comprising a perimeter wall (460) extending between the first skin (110, 210, 310, 410) and the second skin (112, 212, 312, 412) along at least one edge of the aerospace panel (100, 200, 300, 400), in, The first skin (110, 210, 310, 410), the second skin (112, 212, 312, 412), the first truss structure (114, 214, 314, 414) and the surrounding wall (460) together form the single integral jointless structure.

6. The aerospace panel (100, 200, 300, 400) of claim 1, wherein: The plurality of truss members (118, 224, 324, 424) include a plurality of X-shaped truss members (118, 224, 324, 424); and Each X-shaped truss member (118, 224, 324, 424) extends between a pair of first nodes (134, 258, 358, 497) on the first skin (110, 210, 310, 410) and a pair of second nodes (134, 258, 358, 497) on the second skin (112, 212, 312, 412).

7. An aerospace vehicle (102, 1200), the aerospace vehicle comprising: A body having one or more aerospace panels (100, 200, 300, 400), each aerospace panel (100, 200, 300, 400) comprising: First skin (110, 210, 310, 410); a second skin (112, 212, 312, 412) spaced apart from the first skin (110, 210, 310, 410); and A truss structure (114, 214, 314, 414) connects the first skin (110, 210, 310, 410) to the second skin (112, 212, 312, 412), the truss structure (114, 214, 314, 414) comprising a plurality of truss members (118, 224, 324, 424), and each truss member (118, 224, 324 , 424) is integral with the first skin (110, 210, 310, 410) and the second skin (112, 212, 312, 412), so that the first skin (110, 210, 310, 410), the second skin (112, 212, 312, 412) and the first truss structure (114, 214, 314, 414) together form a single integral jointless structure, in: At least one of the first skin (110, 210, 310, 410) and the second skin (112, 212, 312, 412) includes at least one grid region (120, 250, 350, 490) defining a grid (128, 251, 351, 491) configured to eliminate auxiliary printing supports; and The at least one grid region (120, 250, 350, 490) includes a grid formed by grid reinforcements (136, 260, 360, 496) and an array formed by openings (124, 252, 352, 492).

8. A method (700) for manufacturing an aerospace panel (100, 200, 300, 400), the method (700) comprising: printing a first skin (110, 210, 310, 410) and a second skin (112, 212, 312, 412) spaced apart from the first skin (110, 210, 310, 410), and simultaneously printing a plurality of truss members (118, 224, 324, 424) of a first truss structure (114, 214, 314, 414) connecting the first skin (110, 210, 310, 410) to the second skin (112, 212, 312, 412), thereby obtaining a single integral jointless structure, in: At least one of the first skin (110, 210, 310, 410) and the second skin (112, 212, 312, 412) includes at least one grid region (120, 250, 350, 490) defining a grid (128, 251, 351, 491) configured to eliminate auxiliary printing supports; and The at least one grid region (120, 250, 350, 490) includes a grid mesh (128, 251, 351, 491) and an array of openings (124, 252, 352, 492).

9. The method (700) of claim 8, wherein: Printing the first skin (110, 210, 310, 410) and printing the second skin (112, 212, 312, 412) respectively include printing a first grid formed by a reinforcement member together with the first skin (110, 210, 310, 410) and printing a second grid formed by a reinforcement member together with the second skin (112, 212, 312, 412); and Printing the plurality of truss members (118, 224, 324, 424) includes printing each truss member (118, 224, 324, 424) to extend between a first node (134, 258, 358, 497) defined at an intersection of the first grid formed by the reinforcement members (132, 262, 368) and a second node (134, 258, 358, 497) defined at an intersection of the second grid formed by the reinforcement members (132, 262, 368), In the at least one grid region (120, 250, 350, 490), the grid mesh (128, 251, 351, 491) includes one or more grids formed by grid reinforcements (136, 260, 360, 496).

10. The method (700) of claim 9, wherein: Printing the first grid formed by the reinforcement member and printing the second grid formed by the reinforcement member respectively include: printing the first grid formed of reinforcement members (132, 262, 368) to form one or more first grid squares (246); and printing the second grid formed by reinforcement members (132, 262, 368) to form one or more second grid squares (246); The first grid square (246) is offset from the second grid square such that each first node is aligned with a geometric center of one of the second grid squares when the aerospace panel (100, 200, 300, 400) is viewed in a direction normal to the first skin (110, 210, 310, 410); and The one or more grids formed by the grid reinforcements (136, 260, 360, 496) form one or more grid grid (128, 251, 351, 491) squares, and the one or more grid grid squares correspond to the one or more first grid squares (246) or the one or more second grid squares (246) of the skin where the grid formed by the grid reinforcements (136, 260, 360, 496) is located.

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