Additive metal rifle system and manufacturing method

Abstract

Rifle systems and methods of making the same are provided. The rifle system is made using alternative manufacturing methods, such as advanced additive manufacturing ("AM") techniques, also referred to as 3D printing. Further included are an improved trigger housing, an improved bolt retention mortise system configured for bilateral operation, an improved magazine well, an improved trunnion, and a bilateral operation release assembly.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application Serial No. 63 / 524.571, filed June 30, 2023, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This invention generally relates to firearms. More specifically, this invention relates to additive metal rifle systems and methods of manufacturing additive metal rifles. Background Technology

[0004] The G36 rifle family was originally designed in the early 1990s as a replacement for the aging Cold War-era wheel-operated G3k and G3A1 rifles. The G36 is constructed from plastics and lightweight polymers to create a lightweight assault rifle. The use of plastics and lightweight polymers in the rifle's construction, particularly in the receiver, presents durability and resilience issues. These rifles also wear out quickly, especially at high temperatures, and are difficult to repair or servicing.

[0005] The G36's operational range is for use in cold climates, such as in potential battles between the Soviet Union and NATO countries. Therefore, the G36's design is based on Cold War-era German and NATO requirements, which are now decades outdated. The design is suited to cold climates and has a low magazine cycle rate—only 3-5 magazines in fully automatic mode. Under these conditions, the drawbacks of the plastic and lightweight polymer construction are less pronounced. However, in modern combat environments where typical fighters operate in 100-degree Fahrenheit temperatures, extreme altitudes (regardless of elevation), sandy terrain, and mountainous landscapes, often in the Middle East or Afghanistan, these drawbacks become highly problematic.

[0006] The original G36 rifle could only be constructed using injection molding. No other standard level of manufacturing process could produce a receiver body that could be molded. Therefore, the original G36 was made of injection-molded nylon 66, a material that becomes brittle at high temperatures, causing a rotational delay in the "encapsulated" cast iron trunnion unit, resulting in inaccurate firing. Under typical modern warfare conditions, the plastic G36 quickly began to malfunction. In fact, a 2015 report by the Fraunhofer Institute for Ernst Mach and the German Defense Technology Agency stated that when temperatures rise by 30 degrees Celsius or above, the hit probability of the predominantly plastic G36 weapon at 100 meters drops to only 7%. This is far from the 90% hit probability required by the German Federal Armed Forces at that distance. Such problems are almost universal in plastic firearms. Nevertheless, many firearms continue to be made using plastic due to its low cost and ease of production.

[0007] Besides issues with the materials used in its construction, the G36 suffers from numerous other shortcomings. The G36's trigger housing / firing control system is manufacturer-proprietary and not NATO standard. Despite being labeled a "modular rifle system," the initial G36s used only their proprietary 5.56 magazines, not the standard NATO Standardization Protocol (STANAG) NATO M16 magazines. Furthermore, the grips are not interchangeable, and the rifle cannot be serviced by ordinary soldiers. Additionally, the bolt catch being in the lower position when wearing gloves poses a safety hazard. The catch only functions when the bolt is open and needs to be closed, creating another safety issue. The gas block is not adjustable for suppressors or marine environments, leading to a higher failure rate. The G36 uses a non-NATO weapon optics system with an unlocked mounting area, preventing the establishment of a true MOA (Mean Occlusion) or accuracy base. This interface between the plastic receiver body and the dual optical sight carrying handle becomes a weak point in the rifle. Finally, aging G36s are difficult to repair, and spare parts are scarce.

[0008] It would be beneficial to provide a new rifle that can solve the problems of the G36 rifle family and similar weapon families. It would be beneficial to provide a new rifle that performs well in modern combat environments. To this end, it would be beneficial to provide a rifle made of more durable metal materials. Furthermore, it would be beneficial to provide a method for manufacturing such a rifle in an efficient and cost-effective manner. Summary of the Invention

[0009] This invention includes a rifle system and a method of manufacturing the same. The rifle system is manufactured using alternative manufacturing methods, such as advanced additive manufacturing (“AM”) technology, also known as 3D printing. In some embodiments, the rifle system is a 5.56 NATO caliber, gas-operated semi-automatic rifle. Some embodiments of the invention include an improved trigger housing. Some embodiments of the invention include an improved bolt holding catch system configured for bilateral operation. Some embodiments of the invention include an improved magazine well. Some embodiments of the invention include an improved trunnion. Some embodiments of the invention include a bilaterally operated release assembly.

[0010] In some embodiments, additive manufacturing techniques help to form components that are thinner, stronger, more balanced, or otherwise superior to similar components formed using conventional processes.

[0011] The foregoing and other objectives are intended to illustrate the invention and not to limit it. Many possible embodiments of the invention may exist, and these embodiments will become apparent upon studying the following description and the accompanying drawings, which form a part of it. Various technical features and sub-combinations of the invention may be practiced without reference to other technical features and sub-combinations. Other objects and advantages of the invention will become apparent from the accompanying drawings and the following description, in which embodiments of the invention and their various features are illustrated and exemplified. Attached Figure Description

[0012] This document sets forth and illustrates preferred embodiments of the invention in the accompanying drawings / illustrations, demonstrating the applicant's best approach to applying these principles.

[0013] Figure 1 This is a perspective view of the rifle of the present invention according to some embodiments.

[0014] Figure 2 yes Figure 1 Right view of a rifle.

[0015] Figure 3 yes Figure 1 Left view of a rifle.

[0016] Figure 4 yes Figure 1 Rear view of a medium rifle.

[0017] Figure 5 yes Figure 1 Front view of a medium rifle.

[0018] Figure 6 yes Figure 1 A top view of a rifle.

[0019] Figure 7 yes Figure 1 A bottom view of a medium rifle.

[0020] Figure 8 yes Figure 1 A perspective view of the receiver body of a medium rifle.

[0021] Figure 9 yes Figure 8 Right view of the main body of the middle casing.

[0022] Figure 10 yes Figure 8 Left view of the main body of the middle casing.

[0023] Figure 11 yes Figure 8 Rear view of the main body of the middle casing.

[0024] Figure 12 yes Figure 8 Front view of the main body of the middle casing.

[0025] Figure 13 yes Figure 8 Top view of the main body of the middle casing.

[0026] Figure 14 yes Figure 8 Bottom view of the main body of the middle casing.

[0027] Figure 15A dual-operated magazine release assembly is shown in some embodiments of the present invention.

[0028] Figure 16 Shown at a slightly rotated angle Figure 15 The dual-sided magazine release assembly.

[0029] Figure 17 yes Figure 15 Top view of the dual-sided magazine release assembly.

[0030] Figure 18 This is a perspective view of an trunnion assembly according to some embodiments of the present invention.

[0031] Figure 19 yes Figure 18 Right view of the trunnion assembly.

[0032] Figure 20 yes Figure 18 Left view of the middle trunnion assembly.

[0033] Figure 21 yes Figure 18 Rear view of the trunnion assembly.

[0034] Figure 22 yes Figure 18 Front view of the middle shaft assembly.

[0035] Figure 23 yes Figure 18 Top view of the trunnion assembly.

[0036] Figure 24 yes Figure 18 Bottom view of the trunnion assembly.

[0037] Figure 25 This is a right view of a casing assembly according to some embodiments of the present invention, the casing assembly including... Figure 8 The main body of the casing, Figure 15 The dual-sided operated magazine release assembly and Figure 18 The trunnion assembly in the middle.

[0038] Figure 26 yes Figure 25 Left view of the middle casing assembly.

[0039] Figure 27 Viewed from the right perspective Figure 25 Partial exploded view of the middle casing assembly.

[0040] Figure 28 Viewed from the left perspective Figure 25 Partial exploded view of the middle casing assembly. Detailed Implementation

[0041] Exemplary embodiments of the present invention include an additive metal rifle system and a method for manufacturing the same. For example... Figure 1-7 As shown, in some embodiments, the rifle is a 5.56 NATO caliber, gas piston semi-automatic rifle.

[0042] Some embodiments of the present invention include a casing body and a method for manufacturing the same. Figure 8-14 Exemplary receiver bodies of some embodiments are shown. In some embodiments, the receiver body is 3D printed using additive metal (e.g., additive powder A6061-RAM2C). Additive metal has hundreds of times the strength and heat resistance of nylon 6060. Furthermore, additive metal facilitates the formation of parts that are several times thinner in many areas, and firearms with more uniform balance and accuracy approaching 1 minute of arc (“MOA”). In some embodiments, the receiver body of the present invention is a single piece, rather than the three pieces required in existing firearm families.

[0043] In some embodiments, the receiver body is 3D printed on top of the build plate. In some such embodiments, the receiver body is 3D printed at an angle relative to the build plate, for example, at an angle that minimizes or eliminates the post-build machining that would otherwise be required on critical surfaces. In some embodiments, critical surfaces include the bolt carrier interface surface, the magazine rail surface, and the cam pin control surface. In some embodiments, these surfaces need to be unsupported, which can be achieved without additional machining due to the use of tilted 3D printing.

[0044] Some embodiments of the invention include a magazine well that serves not only as a combat impact surface but is also adapted to withstand large stress areas with significant impact loads. In some embodiments, this area is a single integral piece, which greatly improves the overall strength and service life of the entire system. In some embodiments, the magazine well is configured to use the NATO Standardized Protocol 5.56 NATO magazine type, which is advantageous compared to rifle families such as the G36 that require dedicated magazines. In some embodiments, the magazine ejection interface mechanism is located on both sides of the receiver body for bilateral operation. In some embodiments, the magazine ejection component is also configured to be compatible with NATO AR rifle family standards. In some embodiments, the "recessed" side is flared to provide operational advantages during rapid loading under pressure.

[0045] Some embodiments include a release assembly 200. In some embodiments, the release assembly 200 is a side-operated magazine release assembly for a High Accuracy Anti-Material Rifle (HAAMR). In some embodiments, such as Figure 15-17As shown, the release assembly 200 includes a magazine catch plate 210, a right magazine release button 220, and a left magazine release button 230. In some such embodiments, the magazine catch plate is connected to the left magazine release button using a connecting pin. In some embodiments, the magazine catch plate and the right magazine release button are connected using a pivot pin. In some embodiments, a cavity in the magazine is used to receive the catch plate, which secures the magazine in place. A right magazine release spring 222 is connected to the right magazine release button 220, and a left magazine release spring 232 is connected to the left magazine release button 230. In some such embodiments, the force of the release springs holds the release button in a locked state. In some embodiments, such as Figure 17 As shown, magazine release buttons 220 and 230 have opposing, angled noses connected to each other—left magazine release button nose 224 and right magazine release button nose 234.

[0046] In some embodiments, in the "locked state," the right magazine release button 220 is naturally biased outward away from the receiver body 100, and the left magazine release button 230 is naturally biased inward toward the interior of the magazine housing. In the locked state, the right magazine release button 220 is restricted by the receiver body 100 to operate only linearly, while the left magazine release button 230 is restricted by both sides of the receiver body to operate rotatably within a predetermined arc. In some such embodiments, the left magazine release button 230 is connected to a magazine catch plate 210 such that rotating the left magazine release button also rotates the magazine catch plate away from the magazine (releasing the magazine). In some embodiments, the catch plate is inserted into the left magazine release button and secured in place by a single pivot pin. Therefore, no additional components are required.

[0047] In these embodiments, when the operator engages / presses the right magazine release button 220, it slides linearly toward the interior of the assembly, its angled nose contacting the angled nose of the left magazine release button 230. The angled surface guides the left magazine release button 230 (attached to the magazine catch plate 210) to rotate toward the exterior of the assembly, which causes the magazine catch plate to move away from the magazine, thereby releasing the magazine. Accordingly, pressing only the left magazine release button 230 does not cause the right magazine release button 220 to move (because it is biased outward), but it does cause the magazine catch plate 210 to rotate outward, thereby releasing the magazine. Therefore, pressing either button will cause the magazine to release. Furthermore, when the operator releases either button, the assembly returns to the locked state due to their respective bias springs 222 and 232.

[0048] In some embodiments, when the right magazine release button 220 is triggered, the noses of the right magazine release button 220 and the left magazine release button 230 overlap. The left magazine release button 230 and the magazine catch plate 210 rotate clockwise (outward) to release the magazine. If instead the left magazine release button 230 is triggered, rotation occurs, but the right magazine release button 220 does not engage because it is biased away from the left magazine release button 230. In either case, the magazine is released.

[0049] In some embodiments, the right and left magazine release buttons are mirror-symmetrical in structure, allowing their structures and shapes to be interchanged. Therefore, in these embodiments, in the "locked state," the left magazine release button is naturally biased outward away from the receiver body, and the right magazine release button is naturally rotated-biased inward toward the interior of the magazine housing. In the locked state, the left magazine release button is restricted by the receiver body to operate only linearly, while the right magazine release button is restricted by both sides of the receiver body to operate rotatably within a predetermined arc.

[0050] Some embodiments of the invention include a trigger housing adapted for AR / M16 ergonomics and capable of using any readily available commercial or military-grade AR / M16 trigger assembly or component. Therefore, operators do not require retraining on new methods for selecting specialized weapons or on how to maintain weapon trigger systems.

[0051] Some embodiments of the invention include a bolt holding latch system configured for bilateral operation via either the left or right index finger. Either hand can push the bolt forward or hold it open. In some embodiments, the system is configured to work with NATO standard grips or any commercially available type of grip. In some embodiments, the trigger housing is printed from ultralight, high-strength porous aluminum additive manufacturing (AM) powder.

[0052] like Figure 18-24 As shown, some embodiments include a multi-piece trunnion assembly 300. Some such embodiments include a trunnion block 310. In these embodiments, the upper and lower portions of the trunnion block 310 are two distinct parts. In some embodiments, the trunnion assembly 300 includes a trunnion plate 320. In some embodiments, one or more components of the trunnion assembly are made using additive metal (e.g., components equivalent to 8620 tool steel printed using additive manufacturing technology). In these embodiments, this design variation, combined with additive composition, is significantly superior to any other type of metal or process used on any weapon family in the world.

[0053] Some embodiments of the invention include a receiver body with a print pin location to receive an ACR grip for OEM adaptation. This "ACR" universal grip is one of the most popular and ergonomic grip units.

[0054] In some embodiments, the present invention facilitates cleaning, maintenance, repair, and reconfiguration. In some such embodiments, various components of the invention, such as the barrel, trunnion block, trunnion plate, bolt head, or latch, can be easily removed and replaced, thereby facilitating the repair or reconfiguration of the firearm. In some embodiments, reconfiguring the firearm includes reconfiguring the firearm to be loaded with different ammunition, such as ammunition of different calibers. In some embodiments, reconfiguring the firearm from a first caliber to a second caliber includes removing and replacing the first barrel and the first bolt head with a second barrel and a second bolt head, respectively. In some such embodiments, a first trunnion plate and a first trunnion block are used for each caliber configuration, depending on the first and second calibers and the dimensions of the trunnion block and trunnion plate. In other such embodiments, one of the first trunnion plate and the first trunnion block is replaced with a corresponding second trunnion plate or second trunnion block, depending on the circumstances. In still other such embodiments, each of the first trunnion plate and the first trunnion block is replaced with a corresponding second trunnion plate and a second trunnion block. In some embodiments, reconfiguring the firearm does not require replacing the barrel and / or the bolt head.

[0055] It should be understood that the systems and methods described herein include and are applicable to weapons of various calibers. In some embodiments, this includes the M5 standard, the 6.8×51 caliber standard used by the U.S. Army, the caliber standard used in the U.S. Army's Lance program, and the 7.62×51 caliber standard. Nevertheless, the systems and methods described herein cover and are applicable to the manufacture of weapons and receivers of smaller and larger calibers.

[0056] The foregoing and other objectives are intended to illustrate the invention and not to limit it. Many possible embodiments of the invention may exist, and these embodiments will become apparent upon reading the following description and the accompanying drawings, which form a part of it. Various technical features and sub-combinations of the invention can be implemented without reference to other technical features and sub-combinations. Other objects and advantages of the invention will become apparent when taken into account the accompanying drawings and the following description, in which embodiments of the invention and their various features are illustrated and exemplified.

Claims

1. A firearm comprising: a single-piece magazine body formed from additive metal in an additive manufacturing process, the single-piece magazine body defining a horizontal channel and a magazine well extending perpendicularly from the horizontal channel; a barrel extending from the horizontal channel of the magazine body; and a multi-piece trunnion assembly for securing the barrel to the magazine body, the trunnion assembly being at least partially located within the horizontal channel of the magazine body; wherein the trunnion assembly includes a trunnion plate and a trunnion block selectively secured with the trunnion plate.

2. The firearm of claim 1, further comprising: a bolt head engaged with the trunnion plate; and a locking nut securing the barrel to the trunnion block.

3. The firearm of claim 2, wherein the trunnion plate is directly connected to the magazine body, wherein the trunnion block is directly connected to the magazine body, and wherein the trunnion block and the trunnion plate are directly connected to each other.

4. The firearm of claim 2, wherein the trunnion block is formed from additive metal in an additive manufacturing process.

5. The firearm of claim 2, further comprising: first and second magazine release buttons connected with the magazine body and located on respective first and second sides of the firearm for selective independent user engagement therewith, each of the first and second magazine release buttons being movable between a respective engaged configuration and a disengaged configuration; and a magazine catch plate extending from the first magazine release button and movable from a retained position to a retracted position by moving the first magazine release button from its disengaged configuration to its engaged configuration, wherein retaining the second magazine release button in its engaged configuration will prevent movement of the first magazine release button away from its engaged configuration.

6. The firearm of claim 5, further comprising: a first pin for securing the first magazine release button to the magazine; wherein moving the first magazine release button between its engaged and disengaged configurations comprises rotating the first magazine release button about the first pin, and wherein moving the second magazine release button from its disengaged configuration toward its engaged configuration comprises linearly moving the second magazine release button toward the first pin, thereby rotating the first magazine release button away from its disengaged configuration.

7. The firearm of claim 6, further comprising first and second springs connected with the respective first and second magazine release buttons, the first and second springs being configured to bias the respective first and second magazine release buttons toward the respective disengaged configurations.

8. The firearm of claim 7, wherein each of the first and second magazine release buttons includes a user engagement member and a flange extending therefrom, respective distal ends of the flanges defining corresponding first and second canted noses. ​ ​ 9. The firearm of claim 8, wherein when the second release button is held in its disengaged configuration, movement of the first release button toward its engaged configuration causes the first ramped nose to rotate away from the second ramped nose; and wherein when the first release button is in its disengaged configuration, movement of the second release button toward its engaged configuration causes the second ramped nose to push into the first ramped nose, thereby creating a transverse force that biases the first release button away from its disengaged configuration.

10. The firearm of claim 6, wherein the first and second magazine release buttons are connected by overlapping of the respective first and second ramped noses.

11. A magazine release assembly for a firearm, comprising: a magazine plate; a first magazine release button connected with the magazine plate, wherein the first magazine release button is configured to rotate about an axis upon engagement, thereby causing the magazine plate to move; a second magazine release button connected with the first magazine release button, wherein the second magazine release button is configured to move linearly upon engagement.

12. The release assembly of claim 11, wherein the second magazine release button is further configured to strike the first magazine release button upon engagement, thereby causing the first magazine release button to rotate.

13. The release assembly of claim 11, further comprising a first spring connected with the first magazine release button and a second spring connected with the second magazine release button, the first and second springs configured to return the first and second magazine release buttons to their original positions upon engagement.

14. The release assembly of claim 11, wherein the first and second magazine release buttons each include a flange, a distal end of each flange defining a ramped nose.

15. The release assembly of claim 14, wherein the first and second magazine release buttons are connected with one another by overlapping of their respective ramped noses.

16. The release assembly of claim 15, wherein the second magazine release button is further configured to strike the first magazine release button upon engagement, thereby causing the first magazine release button to rotate.

17. The release assembly of claim 16, further comprising a first spring connected with the first magazine release button and a second spring connected with the second magazine release button, wherein the first and second springs are configured to return the first and second magazine release buttons to their original positions upon engagement.

18. A method of changing a caliber of a firearm, the firearm comprising: a chassis body defining a horizontal channel and a magazine well extending perpendicularly from the horizontal channel; and a multi-piece trunnion assembly at least partially within the horizontal channel of the chassis body, the multi-piece trunnion assembly comprising: a trunnion plate engaged with a first bolt head; and a trunnion block engaged with a first barrel, wherein the method comprises: separating the trunnion block from the chassis body; ​ removing the trunnion block from the receiver body while the trunnion plate is held fixed to the receiver body; separating the first barrel from the trunnion block; connecting a second barrel with the trunnion block; positioning the trunnion block relative to the receiver body and the trunnion plate; and securing the trunnion block to the receiver body; wherein the first and second barrels are associated with respective first and second calibers.

19. The method of claim 18, further comprising: separating the trunnion plate of the trunnion assembly from the receiver body; removing the trunnion plate from the receiver body; replacing the first bolt head with a second bolt head; positioning the trunnion plate relative to the receiver body; and securing the trunnion plate to the receiver body, wherein the first and second bolt heads are associated with respective first and second calibers.

20. The method of claim 19, wherein the receiver body is a single-piece receiver body formed from an additive metal in an additive manufacturing process.

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