Structure and method for combined additive manufacturing

Abstract

A vehicle component and a method of forming a vehicle component. The vehicle component includes an additive manufacturing (AM) structure having a first end and a second end opposite the first end. The AM structure includes a path from the first end to the second end and a non-AM structure passing along the path from the first end to the second end. The non-AM structure and the AM structure are fixedly connected to each other at a junction.

Description

[0001] Cross - reference to related applications

[0002] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 417908, entitled SCAFFOLDING BASED STRUCTURE, filed on October 20, 2022, the entire content of which is incorporated herein by reference. Technical field

[0003] The present disclosure generally relates to combined additive - manufactured and non - additive - manufactured components and methods of forming combined components. Background art

[0004] Additive manufacturing (AM) systems can produce metal structures (referred to as build parts) having geometrically complex shapes, including some shapes that are difficult or impossible to form using traditional manufacturing processes. (AM) techniques are used to generate build parts layer - by - layer (i.e., slice - by - slice). The process can be repeated to form the next slice of the build part, and so on. Since each layer is deposited on the previous layer, AM allows the formation of structures that were previously impossible to form by traditional non - AM manufacturing techniques.

[0005] Although AM offers several advantages, often any one or combination of efficiency, cost, and / or project scale can result in AM not being suitable for forming all parts. Summary of the invention

[0006] A brief overview of one or more aspects of the present invention is given below to provide a basic understanding of these aspects. This overview is not an extensive review of all contemplated aspects and is neither intended to identify key or critical elements of all aspects nor to describe the scope of any or all aspects. Its purpose is to present some concepts of one or more aspects in a simplified form as a prelude to the more detailed description that follows.

[0007] In some aspects of the present disclosure, a combined component or structure (which may be a vehicle structural component) includes an additive - manufactured (AM) structure having a first end and a second end opposite the first end. The AM structure includes a path from the first end to the second end. The component further includes a non - AM structure passing along the path from the first end to the second end, wherein the non - AM structure and the AM structure are fixedly connected to each other at the connection.

[0008] In some aspects, the techniques described herein relate to a method of forming a vehicle component, the method comprising: obtaining an additive manufacturing (AM) structure having a first end and a second end opposite the first end, wherein the AM structure includes a path from the first end to the second end; obtaining a non-AM structure passing along the path from the first end to the second end; and fixedly coupling the AM structure and the non-AM structure to each other at the junction.

[0009] Other aspects will become apparent to those skilled in the art from the following detailed description, wherein only a few exemplary embodiments are shown and described by way of illustration. As will be appreciated by those skilled in the art, the concepts described herein can have other and different embodiments and can be modified in several other respects, all without departing from the disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The various features and aspects of the techniques described herein are set forth in the appended claims and drawings as follows. In the following description, throughout the specification and the drawings, like parts are respectively marked with the same reference numerals. The drawings are not necessarily to scale, and in some instances, certain figures may be shown in exaggerated or generalized form for clarity and brevity. However, when read in conjunction with the following detailed description of the illustrative aspects, the present disclosure itself, as well as the preferred mode of use, its further objects and advantages will be better understood.

[0011] Figures 1A - 1D Corresponding side views of an example powder bed fusion (PBF) system that can be used in various aspects of the present disclosure during different operating stages are shown.

[0012] Figure 2A An example of a wire drawing process that can be used in various aspects of the present disclosure is shown.

[0013] Figure 2B An example of an extrusion process that can be used in various aspects of the present disclosure is shown.

[0014] Figure 2C Examples of stamping or drawing methods and apparatuses that can be used in various aspects of the present disclosure are shown.

[0015] Figure 2D Examples of rolling manufacturing methods and apparatuses that can be used in various aspects of the present disclosure are shown.

[0016] Figure 3A Examples of mandrel bending methods and apparatuses that can be used in various aspects of the present disclosure are shown.

[0017] Figure 3BShows an example of a push bending method and apparatus that can be used in aspects of the present disclosure.

[0018] Figure 3C Shows an example of a roll bending apparatus and method that can be used in aspects of the present disclosure.

[0019] Figure 3D Shows an example of a stretch forming method and apparatus that can be used in aspects of the present disclosure.

[0020] Figure 4 Shows an example of a combined AM and non-AM structure according to aspects of the present disclosure.

[0021] Figure 5 Is a partial isometric view of an example of a connected combined structure according to aspects of the present disclosure.

[0022] Figure 6 Is a partial isometric view of an example of a connected combined structure according to aspects of the present disclosure.

[0023] Figure 7A and Figure 7B Shows an example of a cross-section of an AM component and a non-AM structure according to aspects of the present disclosure.

[0024] Figure 8A and Figure 8B Shows another example of a cross-section of an AM component and a non-AM structure according to aspects of the present disclosure.

[0025] Figure 9 Is a partial isometric view of an example of a connected combined structure having an AM structure and a non-AM structure according to aspects of the present disclosure.

[0026] Figure 10 Is a partial isometric view of an example of a connected combined structure having an AM structure and a non-AM structure according to aspects of the present disclosure. Detailed Description

[0027] The following detailed description, presented in conjunction with the accompanying drawings, is intended to provide a description of various exemplary embodiments of the concepts disclosed herein and is not intended to represent the only embodiments in which the present disclosure may be practiced. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure and to fully convey the scope of the concepts to those skilled in the art. However, the present disclosure may be practiced without these specific details. In some instances, well-known structures and components may be shown in block diagram or simplified form, or may be omitted entirely, in order to avoid obscuring the various concepts presented throughout the present disclosure.

[0028] Ⅰ. Terms

[0029] Throughout the specification, references to "one aspect" or "an aspect" and "one example" or "an example" mean that a particular feature, structure, or characteristic described in connection with the embodiment or example can be a feature included in at least one example of the invention. Thus, the phrases "in one aspect" and "one example" that appear in various places throughout the specification do not necessarily all refer to the same example. Additionally, the particular features, structures, or characteristics can be combined in any suitable combination and / or sub - combination in one or more embodiments or examples.

[0030] As used in this disclosure, the term "exemplary" means serving as an example, instance, or illustration and should not necessarily be construed as preferred or advantageous over other embodiments presented in this disclosure.

[0031] Throughout the disclosure, the terms "substantially" or "approximately" can be used as modifiers of the geometric relationship between elements or of the shape of an element or component. While the terms "substantially" or "approximately" are not limited to specific variations and can encompass any variation that would be understood by a person of ordinary skill in the art as an acceptable level of variation, some examples are provided below. In one example, the terms "substantially" or "approximately" can include a variation of less than 10% in the dimensions of an object or component. In another example, the terms "substantially" or "approximately" can include a variation of less than 5% in the dimensions of an object or component. If the terms "substantially" or "approximately" are used to define the angular relationship between one element and another, a non - limiting example of the terms "substantially" or "approximately" can include a variation of 5 degrees or less. These examples are not intended to be limiting and can be increased or decreased based on the understanding of acceptable limits by a person skilled in the relevant art.

[0032] For the purposes of this disclosure, when an aspect or article described herein is in a use orientation, directional terms are generally stated relative to a standard reference frame. In some examples, the directional terms are generally stated relative to a left - hand coordinate system.

[0033] Terms such as "a" and "the" are not intended to refer only to a singular entity but also to the general class for which a particular example can be used to illustrate. The terms "a" and "the" can be used interchangeably with the term "at least one". The phrases "at least one of... " and "comprising at least one of... " followed by a list refer to any one of the items in the list and any combination of two or more of the items in the list. Unless otherwise stated, all numerical ranges include their endpoints and non - integer values between the endpoints.

[0034] The terms "first", "second", "third", and "fourth", as well as other numerical values, may be used in this disclosure. It should be understood that these terms are used only in their relative sense unless otherwise specified. In particular, certain components may be present in interchangeable and / or equal multiples (e.g., in pairs). For these components, in the description, the names "first", "second", "third", and / or "fourth" may be applied to the component only for convenience.

[0035] The term "powder bed fusion (PBF)" is used throughout the disclosure. A PBF system may include a variety of additive manufacturing (AM) techniques, systems, and methods. Thus, the PBF systems or processes referred to in this disclosure may include the following printing techniques: direct metal laser sintering (DMLS), electron beam melting (EBM), selective heat sintering (SHS), selective laser melting (SLM), and selective laser sintering (SLS). The PBF fusion and sintering techniques may further include, for example, solid-state sintering, liquid-phase sintering, partial melting, complete melting, chemical bonding, and other bonding and sintering techniques. Although the PBF process is disclosed herein, other 3D printing processes (e.g., direct energy deposition (DED), fused deposition modeling (FDM), stereolithography (SLA), etc.), including those currently envisioned or commercially developed, may be used without departing from the principles of this disclosure. Aspects of this disclosure may additionally relate to non-metal additive manufacturing and / or metal / binder additive manufacturing (e.g., binder jetting), which may dispense with an energy beam source and instead apply a binder or other adhesive to form each layer. In the case of binder jetting, the green or green-state body may be sintered or melted in a furnace and / or infiltrated with bronze or other alloys.

[0036] The term "fusion" may be used throughout the disclosure to describe any permanent adhesion of AM powders or other known materials. In some examples, the term "fusion" may include sintering, melting, and / or adhesion of individual powder particles (e.g., via a binder or adhesive).

[0037] The term "conventional manufacturing" or "non-AM" may be used throughout the disclosure to encompass any manufacturing technique other than AM. Some examples may include subtractive manufacturing techniques (e.g., machining) and / or any one or combination of extrusion, stamping, forging, molding, or casting (to name just a few non-limiting examples). Additionally, non-AM may refer to any known method for forming non-metal components. For example, non-AM may also include components formed from composite materials that include carbon fiber, para-aramid (Kevlar TM) Any one or combination of glass fibers or their substrates, which are bonded or otherwise laminated via a synthetic polymer (e.g., epoxy resin, vinyl ester, polyester resin, or a combination thereof).

[0038] The term "structural component in a vehicle" can include, but is not limited to, a frame, a subframe, or a component that receives loads due to vehicle driving dynamics. In some examples, the term "structural component" can be distinguished from other vehicle components, such as seats, steering wheels, exhaust devices, etc.

[0039] II. Detailed Examples

[0040] An additive manufacturing (AM) system (such as a powder bed fusion (PBF) system) can produce structures with geometrically complex shapes, which include some shapes that are difficult or impossible to form using traditional manufacturing processes. The PBF system creates a build piece layer by layer (i.e., slice by slice). Each slice can be formed by a process of depositing a layer of powder (e.g., metal or metal powder) and melting (e.g., melting and cooling) the area of the metal powder layer that coincides with the cross-section of the build piece in that slice. This process can be repeated to form the next slice of the build piece, and so on.

[0041] However, in certain cases, PBF or AM components or sections may be needed and / or may be best utilized only at certain parts of the overall build or structure. For example, in the case of vehicle components or modular components or structures, due to any one or combination of efficiency considerations, packaging, desired strength, weight, and / or known stresses, and the ability to optimize AM components to known stresses, a portion of a larger structure can be formed using PBF or AM. Other sections of the vehicle component can be formed using non-AM techniques. Generally speaking, aspects of the present disclosure relate to components and methods of forming components, which include PBF and / or AM sections and components formed using non-AM techniques. Further details and examples are provided in the detailed examples below.

[0042] Figures 1A - 1D Corresponding side views showing examples of a PBF system 100 that can be used for aspects of the present disclosure during different operating stages are shown. As described above, Figures 1A - 1D The specific embodiment shown is one of many suitable examples of a PBF system that employs the principles of the present disclosure. It should also be noted that, Figures 1A - 1DThe elements in this disclosure and in other figures are simplified and not necessarily drawn to scale, but may be drawn larger or smaller and / or with less detail for better illustration of the concepts described herein. The PBF system 100 may include a depositor 101 that can deposit each layer of metal powder, an energy beam source 103 that can generate an energy beam, a deflector 105 that can direct or redirect the energy beam to melt and / or sinter the powder material, and a build plate 107 that can support one or more build parts (such as build part 109). The PBF system 100 may also include a build floor 111 positioned within a powder bed container. The walls 112 of the powder bed container. The build floor 111 can gradually lower the build plate 107 such that the depositor 101 can deposit the next layer. In some examples, the entire mechanism may be located within a chamber 113, which can enclose other components, thereby protecting the equipment, enabling atmosphere (e.g., providing an inert environment) and temperature regulation, and reducing the risk of contamination. The depositor 101 may include a hopper 115 and a leveling device 119, the hopper containing powder 117, such as metal powder, and the leveling device can level the top of each deposited layer of powder.

[0043] Specific reference Figure 1A , which shows the PBF system 100 after a slice of the build part 109 has been melted by the energy beam but before the next layer of powder is deposited. In fact, Figure 1A shows the time when the PBF system 100 has deposited and melted a partially completed build part in multiple layers to form the current state of the build part 109. The multiple deposited layers form a powder bed 121, which includes powder that has been deposited but not sintered and / or melted.

[0044] Figure 1B shows the PBF system 100 at a stage where the build floor 111 can lower the powder layer thickness 123. The lowering of the build floor 111 causes the build part 109 and the powder bed 121 to drop by the powder layer thickness 123, such that the top of the build part and the powder bed is lower than the top of the powder bed container walls 112 by an amount equal to the powder layer thickness. In this way, for example, a space with a constant thickness equal to the powder layer thickness 123 can be formed above the top of the build part 109 and the powder bed 121.

[0045] Figure 1C shows the PBF system 100 at a stage where the depositor 101 is positioned to deposit powder 117 into a space formed above the top surfaces of the build part 109 and the powder bed 121 and bounded by the powder bed container walls 112. In this example, the depositor 101 moves above the defined space while releasing powder 117 from the hopper 115. The leveling device 119 can level the released powder to form a powder layer 125 that has the same thickness as the powder layer thickness 123 (seeFigure 1B ) substantially equal thicknesses. Thus, the powder in a PBF system can be supported by a powder material support structure, which can include, for example, build plate 107, build base plate 111, build member 109, walls 112, etc. It should be noted that the thickness shown for powder layer 125 (i.e., powder layer thickness 123( Figure 1B )) is greater than the actual thickness used in the example involving 150 previously deposited layers discussed above Figure 1A .

[0046] Figure 1D FIG. shows PBF system 100 at a stage in which, after depositing powder layer 125( Figure 1C ), energy beam source 103 generates energy beam 127, and deflector 105 applies the energy beam to melt, sinter, and / or fuse the next slice in build member 109. In various exemplary embodiments, energy beam source 103 can be an electron beam source, in which case energy beam 127 constitutes an electron beam. Deflector 105 can include deflection plates that can generate an electric or magnetic field that selectively deflects the electron beam such that the electron beam scans the area designated to be melted. In various embodiments, energy beam source 103 can be a laser, in which case energy beam 127 is a laser beam. Deflector 105 can include an optical system that uses reflection and / or refraction to manipulate the laser beam to scan the selected area to be melted. In various embodiments, deflector 105 can include one or more gimbals and actuators that can rotate and / or translate energy beam source to position the energy beam. In various embodiments, energy beam source 103 and / or deflector 105 can modulate the energy beam, e.g., turn the energy beam on and off as the deflector scans, such that the energy beam is applied only to the appropriate areas of the powder layer. For example, in various aspects of the present disclosure, the energy beam can be modulated by a digital signal processor (DSP). The deflector can include any known system in the art, such as a galvo-scanner or galvanometer and / or raster scanner. It should be noted that while a single energy beam source 103 and / or deflector 105 is shown, aspects of the present disclosure can be used with and can include systems having multiple energy sources and / or deflectors.

[0047] As Figure 1D shown, most of the melting of powder layer 125 occurs in the area of the powder layer that lies on top of the previous slice (i.e., the previously melted powder). An example of such an area is the surface of build member 109. Figure 1DThe melting of the powder layer occurs above the previously melted layer that characterizes the solid of the build 109. The steps outlined above allow for the formation of shapes and structures that cannot be formed otherwise or would be cost-prohibitive or inefficient to form using traditional non-AM manufacturing techniques.

[0048] Figures 2A - 3D Illustrates non-limiting examples of non-AM manufacturing techniques that can be used in various aspects of the present disclosure.

[0049] Figure 2A Illustrates an example of a draw manufacturing method and apparatus that can be used in various aspects of the present disclosure. In drawing, an undrawn material 202a (e.g., metal or its alloy) is pulled through a single die or a series of dies 250a (indicated by arrow 206a) via a pulling device to reduce the diameter or size, change the cross-sectional shape, and / or ensure that the cross-section of the material is uniform along its length. The drawn material 204a exiting the die 250a has a reduced and / or changed cross-section and / or may have altered material properties. Drawing allows for the formation of elongated parts with various cross-sections, which can be post-processed or otherwise further processed into a desired shape by any one or combination of bending, additional draw extrusion steps, cutting, and / or machining (to name just a few examples).

[0050] Figure 2B Illustrates an example of an extrusion manufacturing method and apparatus that can be used in various aspects of the present disclosure. In extruding a material 202b (e.g., metal or its alloy), the material 202b is pressed through a die or a series of dies 250b via a pressing device 206b to reduce the diameter or size, change the cross-sectional shape, and / or ensure that the cross-section of the material is uniform along its length. The extruded material 204b exiting the die 250b has a reduced and / or changed cross-section and / or may have altered material properties. Extrusion allows for the formation of elongated parts with various cross-sections, which can be post-processed or otherwise further processed into a desired shape by any one or combination of bending, additional extrusion steps or drawing, cutting, and / or machining (to name just a few examples).

[0051] Figure 2C Illustrates an example of a stamping or deep drawing method and apparatus that can be used in various aspects of the present disclosure. The terms "stamping" and "deep drawing" may be used interchangeably herein. In stamping, a pressing device (indicated by arrow 206c) provides a pressing force to deform the material (e.g., metal or its alloy) present between a die set 250c. The material 202c is permanently deformed into a desired shape or size.

[0052] Figure 2DAn example of a rolling manufacturing method and apparatus that can be used in aspects of the present disclosure is shown. A raw material or material 202d (e.g., a metal or its alloy) passes through a series of forming rolls 206d to reduce the thickness or otherwise permanently deform the material 202d into a desired shape.

[0053] It should be noted that, according to aspects of the present disclosure, the foregoing non-AM manufacturing techniques can be used alone or in combination to form non-AM manufactured components. However, the techniques described herein are provided only as examples. Any known non-AM techniques can be used in aspects of the present disclosure. Additionally, the foregoing non-AM techniques can be additionally shaped or machined using the methods described in Figures 3A - 3B

[0054] Figure 3A An example of a mandrel bending method and apparatus that can be used in aspects of the present disclosure is shown. For example, a material formed or otherwise manufactured using any of the methods described above with reference to Figures 2A - 2D can be further formed into a desired shape via mandrel bending. Figure 3A A tube or other hollow body 302a, at least one bending die 306a, at least one pressure die 307a, and at least one clamping die 309a are shown. One or more mandrels 308 can be disposed inside the hollow section of the hollow body 302a to prevent the hollow body 302a from wrinkling or undergoing an undesired deformation when the bending die applies a rotational bending force such that the body is bent and permanently deformed into a desired shape between the bending die 306a and the pressure die 306b and the clamping die 309a.

[0055] Figure 3B An example of a push bending method and apparatus that can be used in aspects of the present disclosure is shown. The push bending process can be applied to a material formed or otherwise manufactured using any of the methods described above with reference to Figures 2A - 2D and can be further formed into a desired shape via the mandrel bending process described above with reference to Figure 3A A force applying device (indicated by arrow 306b) can press one or more punch dies 306b into a plurality of pressure dies 307b and 308b to permanently deform the material 302b into a desired shape.

[0056] Figure 3C An example of a roll bending apparatus and method that can be used in aspects of the present disclosure is shown. The roll bending process can be applied to a material formed or otherwise manufactured using any of the methods described above with reference to Figures 2A - 2D and can be further formed into a desired shape via the mandrel bending process described above with reference to Figure 3A and / or the mandrel bending process described above with reference to Figure 3BThe described push-bending process forms the desired shape. The roll-bending equipment may include multiple bending rollers 306c, 307c, and / or 306c. The bending rollers 306c, 307c, and / or 306c may be configured to rotate about a fixed axis. The material 302c may be fed through the rollers 306c, 307c, and / or 308c such that the material 302c is permanently deformed into the desired shape.

[0057] Figure 3D An example of a stretch-forming method and apparatus that can be used in aspects of the present disclosure is shown. The stretch-forming process can be applied to materials formed or otherwise fabricated using any of the methods described above with reference to Figures 2A - 2D and can further be formed into the desired shape via the mandrel-bending process described above with reference to Figure 3A and / or the push-bending process described above with reference to Figure 3B and / or the roll-bending process described above with reference to Figure 2C The stretch-forming equipment may include a bending die 306d, which may be fixed or movable. The material 302d may have a first portion and a second portion clamped via one or more clamps 307d and / or 308d, and a pulling force and / or a bending force may be applied via corresponding bending equipment and / or pulling equipment. The bending force and / or pulling force applied at one or more clamps 307d and / or 308d causes the material 302d to bend into the shape of the bending die 306d.

[0058] As described above, any one or combination of the foregoing non-AM methods or apparatuses can be used to form the non-AM components or structures described herein. It should be noted that the foregoing non-AM methods and apparatuses are provided only as examples. Any known non-AM method and / or apparatus can be used to form the non-AM components or structures described herein and can be combined with any one or combination of the methods and apparatuses described herein.

[0059] Figure 4 An example of a combined AM and non-AM structure according to aspects of the present disclosure is shown. The structure 400 may include a first non-AM structure 402a, a second non-AM structure 402b, and a third non-AM structure 402c. Although an elongated hollow body (e.g., a tube) is shown as an example non-AM structure in Figures 4 - 6 and Figures 9 - 10 it should be noted that any non-AM structure is applicable to the aspects described herein. The foregoing non-AM structures may be formed using non-AM manufacturing techniques and may have any suitable shape. In one example, the non-AM structure may be formed using the methods described above with reference to Figures 2A - 3Dformed by any one or combination of the described devices and methods. In one example, the foregoing non-AM structure may be an elongated hollow or partially hollow body, which may have a circular, oval, square, rectangular, or polygonal cross-section.

[0060] As Figure 4 shown, each of the non-AM structures 402a, 402b, and / or 402 may pass through one or more AM structures. For example, the first non-AM structure 402a may pass through or along the path 403a in the first AM structure 401a and / or the path 403b in the second AM structure 402b. The end of the first non-AM structure 402a may also be received within the paths 407a and / or 407b (in this case, blind paths, i.e., not completely passing through the AM structure) in the third AM structure 401c and / or the fourth AM structure 401d. The second non-AM structure 402b may pass through or along the path 403e in the fifth AM structure 401e or pass through, pass through or along the path 403d in the fourth AM structure 401d, and enter or otherwise be received within the path 405a (which may be a blind path) in the first AM structure 401a. The third non-AM structure 402c may pass through or along the path 403f in the sixth AM structure 401f, pass through or along the path 403c in the third AM structure 401c, and enter or otherwise be received within the path 405d (which may be a blind path) in the third AM structure 401c.

[0061] In some examples, any one, combination, or all of the AM structures discussed above may include features for mounting vehicle components thereon. For example, the AM structure may include mounting features for any one or combination of body panels, suspension components, vehicle propulsion components, safety components, vehicle interior components, and / or may be used to tie together or otherwise structurally connect one or more non-AM components. In one example, the structure 400 may be, for example, a vehicle frame or subframe. Although specific examples are provided above, it should be noted that the aspects described herein apply to any component or series of components that would benefit from combining AM and non-AM structures into one structure.

[0062] The interface between any one or combination of the foregoing non-AM structures and AM structures may include the features described below with reference to Figures 5 - 10 description.

[0063] Figure 5 is a partial isometric view of an example of a connected combined structure 500 including an AM structure and a non-AM structure according to aspects of the present disclosure. The non-AM structure 502 may be, for example, an elongated hollow body, a partial view of which is shown in Figure 5is shown. It should be noted that while a tubular structure is shown, aspects of the present disclosure apply to any non-AM structure (additional examples of which were described above with reference to Figures 2A - 3D ). In one example, the non-AM structure 502 may share features with or be similar to any one or combination of the first non-AM structure 402a, the second non-AM structure 402b, and / or the third non-AM structure 402c in Figure 4 .

[0064] The non-AM structure 502 may have a first end 522a and a second end 522b. The non-AM structure 502 may also include a bonding portion or region 530 configured to pass along a path 503 in the AM component 501. The AM component 501 may be, for example, hollow or partially hollow and may include a first end opening 503a and a second end opening 503b configured to allow the non-AM structure 502 to pass therethrough.

[0065] As Figure 5 shown, the non-AM structure 502 may have perforations or channels 512. In one example, the channels 512 may be a series of holes or other openings that provide fluid communication from the inside of the hollow channel in the non-AM structure 502 to the outside or exterior of the non-AM structure 502. Once the non-AM structure 502 passes through the first end opening 503a and the second end opening 503b of the AM component 501 and the bonding portion or region 530 is aligned such that the channels 512 are located within the AM component 501, an adhesive or other connection medium may be injected or otherwise provided into one or both of the first end 522a and / or the second end 522b of the non-AM structure 502. The connection medium then passes through the channels 512 of the non-AM structure 502 and into the AM component 501. Once the adhesive or connection medium cures, the non-AM structure 502 and the AM component 501 may be permanently connected at the joint to form a combined structure 500.

[0066] The foregoing connection medium may be any known adhesive or foaming adhesive. In some aspects, the connection medium may be a two-part curable adhesive such as epoxy resin, polyurethane or polyurethane foam, expanding or foaming adhesive, or other adhesives. In another example, the adhesive and / or foam may cure when heat is applied, and thus the connected combined structure 500 may be placed in an autoclave or oven to cure the adhesive at the joint.

[0067] It should be noted that although the specific examples above mention that an adhesive or joining medium is added to the non-AM structure 602, the adhesive or joining medium can be added to the openings or channels in the AM component 501 as an alternative or in combination with the above aspects. In this example, the adhesive or joining medium can be added to the AM structure 602 and can flow from the AM structure 602 into the internal channels of the non-AM structure 502.

[0068] Figure 6 is a partial isometric view of an example of a joined composite structure 600 including an AM structure and a non-AM structure according to aspects of the present disclosure. The non-AM structure 602 can be, for example, an elongated hollow body, a partial view of which is shown in Figure 6 As shown. It should be noted that although a tubular structure is shown, aspects of the present disclosure apply to any non-AM structure that undergoes any machining or manufacturing method (additional examples of which are described above with reference to Figures 2A - 3D ). In one example, the non-AM structure 502b can share features with or be similar to any one or combination of the first non-AM structure 402a, the second non-AM structure 402b, and / or the third non-AM structure 402c in Figure 4 .

[0069] The non-AM structure 602 can have a first end 622a and a second end 622b. The non-AM structure 602 can also include a joining portion or region 630 that is configured to pass along a path 603 in the AM component 601. The AM component 601 can be, for example, hollow or partially hollow and can include a first end opening 603a and a second end opening 603b that are configured for the non-AM structure 602 to pass therethrough. Throughout the present disclosure, the terms "channel" or "hollow" can be used. However, it should be noted that although specific examples are provided herein, the path can include a hollow body or channel and can also include partially hollow (e.g., partially outwardly open) and exposed surfaces (e.g., flat or corrugated surfaces located on the outside of the AM structure such that the non-AM structure does not thread through the AM structure but rather the AM structure simply lies on or partially within the non-AM structure and vice versa. For example, the path can be an open path.

[0070] As Figure 5 shown, the non-AM structure 602 can have one or more deformable features 612. In one example, the deformable feature can be a tab-shaped cutout with one end or side connected to the non-AM structure 602. The deformable feature 612 can be, for example, a rectangular tab with three sides cut or otherwise separated from the non-AM structure 602 such that the application of pressure causes one or more deformable features 612 to bend. Although one or more deformable features 612 are shown inFigure 6 are shown as a series of nine rectangular tabs in, but any number or shape of deformable features may be used without departing from the scope of the present disclosure. In one example, once one or more deformable features 612 are bent, a channel may be formed that provides fluid communication from the inside of the hollow channel in the non-AM structure 502 to the outside or exterior of the non-AM structure 502.

[0071] Once the non-AM structure 602 passes through the first end opening 603a and the second end opening 603b of the AM component 601, and the engaging portion or region 630 is aligned such that the deformable features 612 are located within the AM component 601, an adhesive or other connecting medium may be injected or otherwise provided into one or both of the first end 722a and / or the second end 722b of the non-AM structure 702. Pressure may be built up in the non-AM structure 602 by pressurizing and / or supplying the adhesive or connecting medium into the non-AM structure 602 under pressure such that one or more deformable features 612 are bent, as Figure 6 shown. The bending of one or more deformable features 612 may effectively lock or otherwise connect the AM component 601 to the non-AM structure 602.

[0072] In some examples, when one or more deformable features 612 are deformed such that the connecting medium flows into the AM component 601, the connecting medium may also pass through channels formed in the non-AM structure 602. Once the adhesive or connecting medium cures, the non-AM structure 602 and the AM component 601 may be permanently connected at the joint to form the combined structure 600. The combination of one or more deformable features 612 that engage or otherwise expand into the AM component 601 and the connecting medium that cures between the AM component 601 and the non-AM structure 602 may further strengthen the connection between the two components and prevent loosening or failure of the connection due to, for example, torsional loads and / or push-pull loads.

[0073] The foregoing connecting medium may be any known adhesive or foaming adhesive. In some aspects, the connecting medium may be a two-part curable adhesive, such as epoxy resin, polyurethane or polyurethane foam, expanding or foaming adhesive, or other adhesives. In another example, the adhesive and / or foam may cure when heat is applied, and thus the connected combined structure 600 may be placed in an autoclave or oven to cure the adhesive at the joint.

[0074] Figure 7A and Figure 7B shows an example of a cross-section of an AM component 701 and a non-AM structure in accordance with aspects of the present disclosure. In one example, the AM component 701 and the non-AM structure 702 may be the same as those referred to above with reference to Figure 6The described AM component 601 and non-AM structure 602 share features or may be similar to them.

[0075] As Figure 7A and Figure 7B shown, the AM component 701 can have a channel or path 755 extending from an opening at a first end 703a and a second end 703b. The path 755 can have, for example, one or more receiving features 713 configured to receive one or more deformable features 712 at a connection region 730 of the non-AM structure 702. As Figure 7B shown, when one or more deformable features 712 are deformed and bent outwardly, one or more deformable features 712 lock into or otherwise expand into one or more receiving features 713, thereby further strengthening the adhesion at the junction of the AM component 701 and the non-AM structure 702.

[0076] Figure 8A and Figure 8B show another example of a cross-section of an AM component 801 and a non-AM structure 802 in accordance with aspects of the present disclosure. In one example, the AM component 801 and the non-AM structure 802 can share features or may be similar to the AM component 601 and the non-AM structure 602 described above with reference to Figure 6 In addition, as described above, the features described above with respect to Figure 7A and Figure 7B can be used in combination with the features described below (i.e., both the non-AM structure and the AM component can have deformable features and corresponding receiving features).

[0077] As Figure 8A and Figure 8B shown, the AM component 801 can have a channel or path 855 extending from an opening at a first end 703a and a second end 703b. The path 755 can have, for example, one or more deformable features 812. The deformable features 812 can be, for example, rectangular tabs with three sides separated from the path 855 such that application of pressure causes one or more deformable features 812 to bend. Although one or more deformable features 812 are Figure 8A and Figure 8B shown as a series of nine rectangular tabs in

[0078] Figure 8BThe non-AM structure 802 in [ ] can additionally include one or more receiving features 813 that correspond to one or more deformable features 812 and are configured to receive the one or more deformable features 812 at a connection region 830 of the non-AM structure 802. As Figure 8A shown, when the one or more deformable features 812 deform and bend inwardly into the path 855, the one or more deformable features 812 lock into or otherwise expand into the one or more receiving features 813, thereby locking the AM component 801 and the non-AM structure 802 at the connection.

[0079] Similar to the above aspect, in one example, once the one or more deformable features 812 are bent, a channel can be formed that provides fluid communication from the inner side of the hollow channel in the AM component 801 to the path 855 and into the one or more receiving features 813. Thus, when an adhesive or other connection medium is injected or otherwise provided into the AM structure (i.e., as indicated by the arrow 832), pressure can be built up in the AM component 801 by pressurizing and / or supplying the adhesive or connection medium into the AM component 801, causing the one or more deformable features 812 to bend, as Figure 8A shown. Bending the one or more deformable features 812 into the one or more receiving features 813 and curing any adhesive provided therein can effectively lock or otherwise connect the AM component 801 to the non-AM structure 802 to form a combined structure. The combination of the one or more deformable features 812 that engage or otherwise expand into the one or more receiving features 813 and the connection medium cured between the AM component 801 and the non-AM structure 802 can further strengthen the connection between the two components and prevent loosening or failure of the connection due to, for example, torsional loads and / or push-pull loads.

[0080] Although the examples provided above describe providing a connection medium under pressure or constructing a connection medium in pressure to cause one or more deformable features (e.g., Figure 6612 in FIG. 6, 712 in FIG. 7, and / or 812 in FIG. 8) are deformed or otherwise expanded, but one or more deformable features may instead be deformed or expanded by a pressing or expanding device that can provide a bending force to the deformable feature through a mechanical device (such as a borescope). Additionally, the borescope may further include a connection medium or adhesive dispenser for dispensing the connection medium at the connection when the deformable feature is expanded or deformed. In another example, a mandrel having expandable features corresponding to each of the deformable features may be passed into the channels of the AM component and / or the non-AM structure and expanded. As described above, the expansion of the expandable feature may in turn cause the expandable feature to bend.

[0081] In one example that can provide additional advantages in the above aspects, high-pressure gas and / or vacuum and / or a cleaning agent or etchant may be introduced into the AM component and / or the non-AM component to remove any unfused powder and / or contaminants present in the AM structure.

[0082] Figure 9 is a partial isometric view of an example of a connected combined structure 900 including an AM structure and a non-AM structure according to aspects of the present disclosure. The non-AM structure 902 may be, for example, an elongated hollow body, a partial view of which is shown in Figure 9 It should be noted that although a tubular structure is shown, aspects of the present disclosure apply to any non-AM structure (additional examples of which are described above with reference to Figures 2A - 3D ) that is subjected to any processing or manufacturing method. In one example, the non-AM structure 902 may share features with any one or a combination of the first non-AM structure 402a, the second non-AM structure 402b, the third non-AM structure 402c in Figure 4 , 502 in Figure 5 , 602 in Figure 6 , 702 in Figure 7A and Figure 7B and / or 802 in Figure 8A and Figure 8B and may be similar to them. The connection between the non-AM structure 902 and the AM component described below may be used as an alternative to or in combination with any of the connections described herein.

[0083] Figure 9The non-AM structure 902 therein may have a first end 922a and a second end 922b. The non-AM structure 902 may also include a joint portion or a through region that is configured to pass along a path in the AM component 901 from the first end 903a to the second end 903b. The AM component 901 may be, for example, hollow or partially hollow and / or include a path connecting an opening in the first end 903a to the second end 903b. Once the non-AM structure 902 passes through and along the aforementioned path and is properly oriented relative to the AM component 901, the two may be fixed or otherwise connected at the connection 910. It should be noted that although only a single connection 910 is visible in Figure 9 , similar connections may exist at the second end 903b (which is hidden in the view of Figure 9 ).

[0084] The connection 910 may be formed, for example, by welding or otherwise fixing or adhering the non-AM structure 902 to the AM component 901. In some examples, the connection may be formed via welding. Some examples of suitable welded connections may include, but are not limited to, any one or combination of tungsten inert gas (TIG) welding, metal inert gas (MIG) welding, friction stir welding, friction welding (to name just a few examples). Additionally, the connection may be formed via a supersonic particle deposition process, which is commonly referred to as cold spray welding. In one example, cold spray welding may be formed by using an electrically heated high-pressure carrier gas to accelerate metal powder through a supersonic de Laval nozzle, exceeding the critical velocity of particle adhesion. The cold spray bonding mechanism may be a combination of mechanical interlocking and metallurgical bonding formed due to recrystallization at the high-strain particle interface.

[0085] In one example, the outer surface of the non-AM structure 902 and the channel of the AM component 901 may have corresponding threaded surfaces, allowing the non-AM structure 902 to be threaded into the AM component 901. In some examples, any additional connection method described herein may be combined with threading the non-AM structure 902 into the AM component 901 to further strengthen the connection.

[0086] Figure 10 is a partial isometric view of an example of a connected combined structure 1000 including an AM structure and a non-AM structure according to aspects of the present disclosure. The non-AM structure 1002 may be, for example, an elongated hollow body, a partial view of which is shown in Figure 10 . It should be noted that although a tubular structure is shown, aspects of the present disclosure apply to any non-AM structure that is subject to any machining or manufacturing method (additional examples of which are described above with reference to Figures 2A - 3D ). In one example, the non-AM structure 1002 may be associated with Figure 4the first non-AM structure 402a, the second non-AM structure 402b, the third non-AM structure 402c in Figure 5 the non-AM structure 502 in Figure 6 the 602 in Figure 7A and Figure 7B the 702 in Figure 8A and Figure 8B the 802 and / or Figure 9 any one or combination of the 902 in share features, or can be similar to them. The connection between the non-AM structure 1002 and the AM component described below can be used as an alternative to or in combination with any of the connections described herein.

[0087] Figure 10 The non-AM structure 1002 in can have a first end 1022a and a second end 1022b. The non-AM structure 1002 can also include a joint portion or a through region that is configured to pass along a path in the AM component 1001 from the first end 1003a to the second end 1003b. The AM component 1001 can be, for example, hollow or partially hollow and / or include a path connecting the opening in the first end 1003a to the second end 1003b. Once the non-AM structure 1002 passes through and along the aforementioned path and is properly oriented relative to the AM component 1001, the two can be fixed or otherwise connected at the connection 1010. It should be noted that although only a single connection 1010 is visible in Figure 10 only a single connection 1010 is visible, but similar connections can exist at the second end 1003b (hidden in the view of Figure 10 ).

[0088] The connection 1010 can be formed, for example, by bolting, riveting, or otherwise fastening the non-AM structure 1002 to the AM component 1001. In some examples, the non-AM structure 1002 and / or the AM component 1001 can have flanges 1011 that are configured to have one or more fasteners 1012 passing therethrough. Some examples of suitable fasteners include, but are not limited to, any one or combination of rivets, bolts, screws, or self-tapping fasteners, clips, etc. It should be noted that although only a single connection 1010 is shown in Figure 10 only a single connection 1010 is shown, but the combined structure 1000 can include additional connections. For example, similar flanges 1011 and one or more fasteners 1012 can exist at the second end 1003b (hidden in the view of Figure 10 ). Additionally, the features described with respect to Figure 10 can be combined with any one or combination of the connection features and methods described herein.

[0089] Additional aspects of the present disclosure are described in the following items.

[0090] Item 1. A vehicle component, comprising: an additive manufacturing (AM) structure having a first end and a second end opposite the first end, wherein the AM structure includes a path from the first end to the second end; a non-AM structure passing along the path from the first end to the second end; wherein the non-AM structure and the AM structure are fixedly connected to each other at the connection.

[0091] Item 2. The vehicle component according to Item 1, wherein the connection includes at least an adhesive, a weld, a cold spray weld, or a deformable feature.

[0092] Item 3. The vehicle component according to any one of the above items, wherein the connection includes an adhesive, and the non-AM structure includes an opening and an internal portion connecting the opening to the connection, wherein the internal portion is configured to allow the adhesive to flow from the opening to the connection.

[0093] Item 4. The vehicle component according to any one of the above items, wherein the adhesive is an expanding adhesive, and the expansion of the expanding adhesive causes the expanding adhesive to flow through the internal portion.

[0094] Item 5. The vehicle component according to any one of the above items, wherein at least the AM structure or the non-AM structure further includes a deformable feature configured to deform to form at least a part of the connection.

[0095] Item 6. The vehicle component according to any one of the above items, wherein the connection includes an adhesive, the non-AM structure includes an opening and an internal portion connecting the opening to the connection, and the flow of the adhesive through the internal portion deforms the deformable feature to form at least a part of the connection.

[0096] Item 7. The vehicle component according to any one of the above items, wherein the deformable feature is configured to deform in response to a pressure change caused by at least fluid pressure or mechanical force.

[0097] Item 8. The vehicle component according to any one of the above items, wherein the path includes a hollow path through the AM structure, and a part of the non-AM structure passes through the AM structure through the path.

[0098] Item 9. The vehicle component according to any one of the above items, wherein the path includes an open path.

[0099] Item 10. The vehicle component according to any one of the above items, wherein the non-AM structure is at least: a stamped component, an extruded component, a component formed by mandrel drawing; a machined component, or a composite component.

[0100] Item 11. The vehicle component according to any one of the above items, wherein the composite component includes at least one of carbon fiber, para-aramid fiber, or glass fiber.

[0101] Item 12. The vehicle component according to any one of the above items, wherein the non-AM structure is an elongated tube or a closed shape.

[0102] Item 13. The vehicle component according to any one of the above items, wherein the non-AM structure has a bent section, and wherein the bent section is fixedly connected to the connection.

[0103] Item 14. A method of forming a vehicle component, the method comprising: obtaining an additive manufacturing (AM) structure having a first end and a second end opposite the first end, wherein the AM structure includes a path from the first end to the second end; obtaining a non-AM structure passing along the path from the first end to the second end; and fixedly coupling the AM structure and the non-AM structure to each other at a connection.

[0104] Item 15. The method according to Item 14, wherein fixedly coupling the AM structure to the non-AM structure includes at least using an adhesive, welding, cold spray welding, or deforming a deformable feature.

[0105] Item 16. The method according to any one of the above items, wherein the non-AM structure further includes a channel and an opening in fluid communication with the channel at the connection, and wherein using an adhesive includes: providing an adhesive to the channel such that the adhesive flows from the opening to the connection.

[0106] Item 17. The method according to any one of the above items, wherein the adhesive is an expanding adhesive, and wherein expansion of the expanding adhesive causes the expanding adhesive to flow through the channel and the opening.

[0107] Item 18. The method according to any one of the above items, wherein at least the AM structure or the non-AM structure further includes a deformable feature, and wherein fixedly coupling the AM structure and the non-AM structure includes deforming the deformable feature to form at least a part of the connection.

[0108] Item 19. The method according to any one of the above items, wherein the deformable feature is deformed by a force provided by the flow of the adhesive.

[0109] Item 20. The method according to any one of the preceding items, wherein the deformable feature deforms in response to a pressure change caused at least by fluid pressure or mechanical force.

[0110] Item 21. The method according to any one of the preceding items, wherein the path includes an open path.

[0111] The foregoing description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these exemplary embodiments presented in this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein can be applied to other support structures and systems and methods for removing support structures. Accordingly, the claims are not intended to be limited to the exemplary embodiments presented throughout this disclosure, but rather to the full scope consistent with the language of the claims. All structural and functional equivalents of the elements of the exemplary embodiments described throughout this disclosure (known or later developed by those of ordinary skill in the art) are intended to be encompassed by the claims. In addition, nothing disclosed herein is intended to be dedicated to the public, regardless of whether such disclosure is explicitly recited in the claims. No element of any claim is to be construed under the provisions of 35 U.S.C. § 112(f) or similar laws in the applicable jurisdiction, unless the element is expressly recited using the phrase "means for" or, in the case of a method claim, the element is recited using the phrase "step for".

Claims

1. A vehicle structural component, comprising: An additive manufacturing (AM) structure having a first end and a second end opposite the first end, wherein the AM structure includes a path from the first end to the second end; A non-AM structure passing along a path from the first end to the second end, wherein the non-AM structure and the AM structure are fixedly connected to each other at the connection.

2. The vehicle component according to claim 1, wherein, The connection includes at least an adhesive, a weld, a cold spray weld, or a deformable feature.

3. The vehicle component according to claim 2, wherein, The connection includes an adhesive, and the non-AM structure includes an opening and an internal portion connecting the opening to the connection, wherein the internal portion is configured to allow the adhesive to flow from the opening to the connection.

4. The vehicle component according to claim 3, wherein, The adhesive is an expanding adhesive, wherein expansion of the expanding adhesive causes the expanding adhesive to flow through the internal portion.

5. The vehicle component according to claim 1, wherein, At least one of the AM structure or the non-AM structure further includes a deformable feature configured to deform to form at least a part of the connection.

6. The vehicle component according to claim 5, wherein, The connection includes an adhesive, the non-AM structure includes an opening and an internal portion connecting the opening to the connection, and flow of the adhesive through the internal portion deforms the deformable feature to form at least a part of the connection.

7. The vehicle component according to claim 5, wherein, The deformable feature is configured to deform in response to a pressure change caused at least by fluid pressure or mechanical force.

8. The vehicle component according to claim 1, wherein, The path includes a hollow path through the AM structure, and a part of the non-AM structure passes through the AM structure through the path.

9. The vehicle component according to claim 1, wherein, The path includes an open path.

10. The vehicle component according to claim 1, wherein, The non-AM structure is at least one of: a stamped component, an extruded component, a component formed by mandrel drawing; a machined component, or a composite component.

11. The vehicle component according to claim 10, wherein, The composite component includes at least one of carbon fiber, para-aramid fiber, or glass fiber.

12. The vehicle component according to claim 1, wherein, The non-AM structure is an elongate tube or a closed shape.

13. The vehicle component according to claim 11, wherein, The non-AM structure has a bent section, wherein the bent section is fixedly connected to the connection.

14. A method of forming a vehicle component, the method comprising: Obtaining an additive manufacturing (AM) structure having a first end and a second end opposite the first end, wherein the AM structure includes a path from the first end to the second end; Obtaining a non-AM structure passing along a path from the first end to the second end; and Fixedly coupling the AM structure and the non-AM structure to each other at the connection.

15. The method according to claim 14, wherein, Fixedly coupling the AM structure to the non-AM structure includes at least using an adhesive, welding, cold spray welding, or deforming a deformable feature.

16. The method according to claim 15, wherein The non-AM structure further includes a channel and an opening in fluid communication with the channel at the connection, wherein using an adhesive includes: Providing an adhesive to the channel such that the adhesive flows from the opening to the connection.

17. The method according to claim 16, wherein, The adhesive is an expanding adhesive, wherein expansion of the expanding adhesive causes the expanding adhesive to flow through the channel and the opening.

18. The method according to claim 14, wherein, At least the AM structure or the non-AM structure further includes a deformable feature, wherein fixedly coupling the AM structure and the non-AM structure includes deforming the deformable feature to form at least a part of the connection.

19. The method according to claim 18, wherein, The deformable feature is deformed via a force provided by the flow of an adhesive.

20. The method according to claim 18, wherein The deformable feature is deformed in response to a pressure change caused by at least fluid pressure or mechanical force.

21. The method according to claim 14, wherein, The path includes an open path.

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