Portable manufacturing system and method using inflatable tooling

Abstract

This application relates to portable manufacturing systems and methods using expandable tools. A system for manufacturing a workpiece includes a housing having an internal volume. The housing is configured to enclose at least a portion of the workpiece to be manufactured. The system includes an expandable medium disposed within the internal volume between the housing and at least a portion of the workpiece. The expandable medium is configured to expand within the housing such that it applies a positive pressure to at least the portion of the workpiece enclosed by the housing.

Description

Technical Field

[0001] This disclosure relates generally to materials manufacturing, and more specifically to portable manufacturing systems and methods using expandable tools. Background Technology

[0002] Engineered materials (e.g., composite materials) are used in numerous applications. For many manufactured parts, manufacturing processes include bonding, curing, or other processing operations that typically require elevated temperatures and pressures. Industrial autoclaves are commonly used for these processes because they allow for the application of temperature and pressure under controlled conditions. However, the need for autoclave processing can lead to bottlenecks in manufacturing processes because production volumes depend on the autoclave's capacity and require the transport of raw materials or uncured parts to the autoclave and subsequently the removal of cured composite materials. Furthermore, autoclave processing is generally unsuitable for on-site handling, repair, and remote processing needs. Therefore, those skilled in the art continue to conduct research and development work in materials manufacturing. Summary of the Invention

[0003] Examples of systems for portable manufacturing, methods for manufacturing workpieces, and portable manufacturing kits are disclosed. The following is a non-exhaustive list of examples of the subject matter of this disclosure, which may or may not be claimed.

[0004] In the example, the disclosed system includes a housing with an internal volume. The housing is configured to enclose at least a portion of a workpiece to be manufactured. The system includes an expandable medium disposed within the internal volume between the housing and at least a portion of the workpiece. The expandable medium is configured to expand within the housing such that it exerts a positive pressure on the at least portion of the workpiece enclosed by the housing.

[0005] In the example, the disclosed method includes the following steps: (1) surrounding at least a portion of a workpiece within an internal volume of a housing; (2) applying an expandable medium between the housing and the at least portion of the workpiece within the internal volume; (3) inflating the expandable medium; (4) applying a positive pressure to the at least portion of the workpiece; and (5) processing the workpiece in response to the application of the positive pressure.

[0006] In one example, the disclosed kit includes a housing having an internal volume and configured to enclose at least a portion of a workpiece to be manufactured. The kit includes an expandable medium. The expandable medium is configured to be applied within the internal volume between the housing and at least a portion of the workpiece. The expandable medium is configured to expand to apply a positive pressure to at least the portion of the workpiece enclosed by the housing.

[0007] Other examples of systems, methods, and kits will become apparent from the following detailed description, accompanying drawings, and appended claims. Attached Figure Description

[0008] Figure 1 This is a schematic block diagram of an example system for manufacturing workpieces;

[0009] Figure 2 This is a flowchart illustrating an example of a method for manufacturing a workpiece;

[0010] Figure 3 This is a schematic diagram of an example system, depicting the workpiece and expandable medium applied within the housing;

[0011] Figure 4 yes Figure 3 The schematic diagram of the system shown depicts an expandable medium in an unexpanded state;

[0012] Figure 5 yes Figure 4 The schematic diagram of the system shown depicts an expandable medium in an expanded state.

[0013] Figure 6 This is a schematic diagram of an example of the system's casing;

[0014] Figure 7 This is a schematic diagram of an example of a housing and part of a workpiece;

[0015] Figure 8 This is a schematic diagram of an example system, depicting the workpiece and the expandable medium in an expanded state within the housing;

[0016] Figure 9 This is a schematic diagram of an example system, depicting a workpiece in an expanded state and an expandable medium, wherein the housing utilizes movable sides to change its internal volume.

[0017] Figure 10 This is a schematic diagram of an example system, depicting a housing and a second housing connected together to change the internal volume and accommodate the workpiece;

[0018] Figure 11 This is a schematic diagram of an example system, depicting a workpiece on a forming tool and an expandable medium in an unexpanded state within a housing;

[0019] Figure 12 yes Figure 11 The schematic diagram of the system shown depicts an expandable medium in an expanded state;

[0020] Figure 13 This is a schematic diagram of an example system, depicting the workpiece, casting, and expandable medium in an unexpanded state within the housing;

[0021] Figure 14 yes Figure 13 The schematic diagram of the system shown depicts an expandable medium in an expanded state;

[0022] Figure 15 This is a schematic diagram of an example system, depicting the workpiece, covering, and expandable medium in an unexpanded state within the housing;

[0023] Figure 16 yes Figure 15 The schematic diagram of the system shown depicts an expandable medium in an expanded state;

[0024] Figure 17 This is a schematic diagram of an example system, depicting a workpiece and encapsulation elements containing an expandable medium in an unexpanded state within a housing;

[0025] Figure 18 yes Figure 17 The schematic diagram of the system shown depicts an expandable medium in an expanded state;

[0026] Figure 19 This is a schematic diagram of an example system, depicting a workpiece in an expanded state within a housing, a volume-changing element, a volume-constant element, and an expandable medium;

[0027] Figure 20 This is a schematic diagram illustrating an example of a portable manufacturing kit;

[0028] Figure 21 This is a schematic diagram illustrating an example of an aircraft; and

[0029] Figure 22 This is a flowchart illustrating an example of aircraft manufacturing and maintenance methods. Detailed Implementation

[0030] Now for reference Figure 1 and Figures 3 to 19 By way of example, this disclosure relates to a system 100 for portable manufacturing. The following are examples of system 100 according to this disclosure. Examples of system 100 include a plurality of elements, features, and components. All elements, features, and / or components described or shown in one example are not required in that example. Some or all of the elements, features, and / or components described or shown in one example may be combined in various ways with other examples without needing to include other elements, features, and / or components described in those other examples, even if one or more such combinations are not explicitly described or shown by example herein.

[0031] Examples of System 100 utilize portable and modular confinement containers, expandable materials, and associated components (which enable the manufacture of high-quality processed parts outside of an autoclave). Examples of System 100 advantageously facilitate the application of omnidirectional and at least approximately uniform pressure to the surface of the part to be processed. Examples of System 100 advantageously enable structural bonding, volume reduction, and curing using expandable materials with or without adhesives. Examples of System 100 advantageously enable material handling in locations where such processing would otherwise be unavailable.

[0032] Figures 3 to 5 and Figures 7 to 19 Various examples of a system 100 depicted for processing at least a portion 202 of a workpiece 200 are shown. Generally, a portion 202 of a workpiece 200 refers to any part or all of the workpiece 200 that will be processed using the system 100.

[0033] like Figure 1 As shown, in one or more examples, workpiece 200 includes one or more materials 210 (e.g., a first material 212 and a second material 214). In some examples, materials 210 are the same. In some examples, materials 210 are different. In one or more examples, workpiece 200 may also include any other number of materials 210, including substrates, material layers, components, attachments, etc. (which will be joined together during material handling operations). In one or more examples, one or more materials 210 are composite materials comprising one or more composite layers (also referred to as laminations) (e.g., composite parts, components, objects, etc.). In one or more examples, one or more materials 210 are metallic materials (e.g., metallic parts, components, objects, etc.). In one or more examples, one or more materials 210 are ceramic materials (e.g., ceramic parts, components, objects, etc.). In one or more examples, one or more materials 210 are polymeric materials (e.g., polymeric parts, components, objects, etc.).

[0034] Figures 3 to 5 and Figures 7 to 19 Various examples of workpieces 200 to be processed or joined together using system 100 and / or according to method 1000 are shown, along with examples of materials 210. Workpiece 200 may include any suitable number of materials 210 (e.g., material type, material layer, material portion, material component, or part, etc.). In various examples, workpiece 200 includes one or more composite materials, metallic materials, ceramic materials, polymeric materials, thermoplastic materials, thermosetting materials, fiber-reinforced materials, and / or any other suitable material depending on the desired properties of the joined structure.

[0035] In any of these examples, material 210 is treated using system 100 and / or according to method 1000. In one or more examples, material 210 is cured. In one or more examples, material 210 is bonded together by co-curing (e.g., by applying heat and / or pressure). In one or more examples, material 210 is bonded together by co-bonding (e.g., by applying heat and / or pressure). In one or more examples, material 210 is bonded together by secondary bonding (e.g., by applying heat and / or pressure).

[0036] Workpiece 200 can have any suitable one of a variety of different cross-sectional geometries. Material 210 includes multiple material layers (e.g., uncured composite material, cured composite material, metallic material, ceramic material, polymer material, thermoplastic material, thermosetting material, fiber-reinforced material, etc.) and optional adhesive layers, which are bonded together by expansion of expandable medium 120 to apply positive pressure 102 to workpiece 200. In one or more examples, workpiece 200 includes multiple layers of material 210 (e.g., material layers), wherein the multiple layers of material 210 are provided to be treated (e.g., cured or bonded together) by expansion of expandable medium 120 to apply positive pressure 102 to workpiece 200.

[0037] In one or more examples, the expandable medium 120 is placed or positioned relative to the workpiece 200 such that a normal pressure 102 (e.g., an omnidirectional force) is applied to at least one side or surface of the workpiece 200. Figures 3 to 5 As shown, in one or more examples, a first amount of expandable medium 120 is positioned above or on workpiece 200 (e.g., a stack of material layers) such that the expansion of the expandable medium 120 applies a positive pressure 102 to workpiece 200 to compress the material layers during processing. Figure 8 As shown, in one or more examples, a first amount of expandable medium 120 is positioned above or above workpiece 200, and a second amount of expandable medium 120 is positioned below or below workpiece 200, such that the expansion of expandable medium 120 applies a positive pressure 102 to workpiece 200 to compress the material layer during processing.

[0038] like Figure 1 and Figures 3 to 19As shown, in one or more examples, system 100 includes a housing 110 and an expandable medium 120. The housing 110 includes or forms an internal volume 112. The housing 110 is configured to surround at least a portion 202 of a workpiece 200 to be manufactured. The expandable medium 120 is disposed within the internal volume 112 between the housing 110 and at least a portion 202 of the workpiece 200. The expandable medium 120 is configured to expand within the housing 110 such that the expandable medium 120 applies a positive pressure 102 to the at least portion 202 of the workpiece 200 surrounded by the housing 110. In one or more examples, the housing 110 includes a base 114, a cover 116, and a plurality of sides 118. The sides 118 extend between the base 114 and the cover 116. The base 114, the cover 116, and the sides 118 form the internal volume 112.

[0039] In one or more examples, housing 110 serves as a portable and modular space-constrained container or tool that encloses at least a portion (e.g., portion 202) of workpiece 200 being processed (e.g., manufacturing, repairing, joining, etc.). The portability and modularity of housing 110 advantageously enable workpiece manufacturing and / or material handling in locations otherwise unavailable. In one or more examples, housing 110 is constructed (e.g., in size and shape) to accommodate and / or enclose the entire workpiece 200 being processed. In one or more examples, housing 110 is constructed to accommodate and / or enclose a portion (e.g., smaller than the entire workpiece 200) of the workpiece 200 being processed.

[0040] like Figures 3 to 19 As shown, in one or more examples, the workpiece 200 is supported on or by the base 114. In one or more examples, the cover 116 is positioned relative to the base 114 and / or the workpiece 200 such that at least a portion 202 of the workpiece 200 and the expandable medium 120 are positioned within or otherwise constrained within the cover 116, or positioned or constrained between the cover 116 and the base 114. In one or more examples, the cover 116 allows the expandable medium 120 and the workpiece 200 to be loaded within the internal volume 112 of the housing 110. In one or more examples, the cover 116 has or forms a cross-sectional profile corresponding to the cross-sectional shape of the workpiece 200. Providing the cover 116 with a cross-sectional profile corresponding to (e.g., at least approximately matching or complementary to) the cross-sectional shape of the workpiece 200 helps to reduce the internal volume 112 of the housing 110, and thus reduces the amount of expandable medium 120 required.

[0041] In one or more examples, at least a portion of the housing 110 is rigid. In one or more examples, at least a portion of the housing 110 is flexible and non-expandable. In one or more examples, at least a portion of the housing 110 is flexible and expandable. In one or more examples, at least a portion of the housing 110 substantially resists expansion, at least when pressure is applied to the inner surface of the housing 110 by the expandable medium 120. In this way, the pressure applied to the outer surface of the workpiece 200 works in conjunction with the housing 110 to generate a compressive force on the workpiece 200.

[0042] In one or more examples, at least a portion of the base 114, cover 116, and side 118 is rigid (e.g., hard or non-flexible) and non-expandable. In these examples, at least a portion of the base 114, cover 116, and side 118 is made of any suitable material, including but not limited to metallic materials, composite materials, cement materials, ceramic materials, polymeric materials, etc. In these examples, the housing 110 confines the expandable medium 120 and responds to the positive pressure 102 generated by the expandable medium 120 upon expansion. In these examples, the housing 110 is capable of withstanding the pressure generated within the internal volume 112 when the expandable medium 120 expands.

[0043] In one or more examples, at least a portion of the base 114, cover 116, and side 118 is flexible. In one or more examples, at least a portion of the base 114, cover 116, and side 118 is flexible and non-expandable. In one or more examples, at least a portion of at least one of the base 114, cover 116, and side 118 is flexible and non-expandable or expandable. Making at least a portion of at least one of the base 114, cover 116, and side 118 flexible and non-expandable allows the housing 110 to be formed (e.g., more closely matched) and / or contribute to conforming the shape of at least a portion of the workpiece 200 and / or the expandable medium 120 before the expandable medium 120 expands, resulting in a smaller internal volume 112 of the housing 110, and thus reducing the amount of expandable medium 120 required and increasing the portability of the system 100. In these examples, at least a portion of the base 114, cover 116, and side 118 may be made of any suitable flexible and non-expandable material, including but not limited to metal mesh (e.g., chain linker), ceramic mesh, polymer mesh, etc.

[0044] In one or more examples, a workpiece 200 (e.g., a portion 202) is positioned within a housing 110 (e.g., on a base 114) during processing. To apply a suitable compressive force (e.g., normal pressure 102) to the workpiece 200 while it is within the housing 110, it may be necessary to adequately support at least a portion 202 of the workpiece 200 being processed. In one or more examples, the base 114 provides a substantially incompressible surface to support one side of the workpiece 200. In other examples, the system 100 includes a forming tool 148. The forming tool 148 is configured to be placed within an internal volume 112. The forming tool 148 is configured to support at least a portion 202 of the workpiece 200. In one or more examples, the forming tool 148 provides the cross-sectional shape of the workpiece 200 (e.g., a mandrel).

[0045] In one or more examples, the cover 116 is movable relative to the base 114 between an open and a closed state. In one or more examples, the cover 116 includes any suitable elements or features that facilitate the application and / or removal of the expandable medium 120 from the internal volume 112. In one or more examples, the cover 116 includes a removable or openable panel (e.g., a door) that, once positioned relative to the workpiece 200, allows access to the internal volume 112 and the application of the expandable medium 120.

[0046] like Figure 6 and Figure 7 As shown, in one or more examples, at least one of the sides 118 includes an opening 130. The opening 130 is configured to receive at least a portion 202 of the workpiece 200. As an example, the system 100 is capable of processing (e.g., repairing) specific sections or areas of large or elongated instances of the workpiece 200. In these examples, a portion 202 of the workpiece 200 is inserted into the internal volume 112 of the housing 110 through the opening 130.

[0047] In one or more examples, housing 110 includes cap 132. Cap 132 is configured to at least partially cover opening 130. In one or more examples, cap 132 is configured to constrain or retain expandable medium 120 within internal volume 112 (e.g., before, during, and / or after expansion of expandable medium 120). In one or more examples, cap 132 is configured to fill a portion of opening 130 between workpiece 200 and side 118. In one or more examples, cap 132 is configured to conform to workpiece 200 placed within opening 130.

[0048] like Figure 9As shown, in one or more examples, the internal volume 112 of the housing 110 is selectively (e.g., controllably) variable. In one or more examples, at least one of the sides 118 is movable relative to the base 114 and the cover 116. The movement of one or more sides 118 relative to the base 114 and the cover 116 enables the selective alteration of the internal volume 112, such as the size and / or shape of the internal volume 112. The selective alteration or variation of the internal volume 112 contributes to a reduction in the internal volume 112 and a corresponding reduction in the amount of expandable medium 120 required to fill the internal volume 112 during expansion. The selective alteration or variation of the internal volume 112 also enables the selective or reactive control and alteration of the pressure 104 within the housing 110 (e.g., within the internal volume 112 and acting on the workpiece 200).

[0049] In one or more examples, one or more of the side portions 118 are coupled to the base 114 and the cover 116 and are releasable from the base 114 and the cover 116. In this way, the internal volume 112 of the housing 110 can be customized based on the arrangement of the side portions 118. In one or more examples, the side portions 118 can be releasably coupled to the base 114 and / or the cover 116 using any of a variety of mechanisms or techniques, such as tongue and groove connections, fasteners, clamps, etc. In one or more examples, one or more of the side portions 118 have two or more components, such as a main side portion or outer side portion 118a and a secondary side portion or inner side portion 118b. In these examples, the inner side portion 118b can be moved relative to the outer side portion 118a to change the size and / or shape of the internal volume 112.

[0050] like Figure 1 and Figure 10 As shown, in one or more examples, system 100 includes a second housing 150. In one or more examples, the second housing 150 is substantially the same as and / or includes substantially the same elements, features, and / or components as housing 110. The second housing 150 includes or forms a second internal volume 152. In one or more examples, the second housing 150 includes a second base 154 and a second cover 156. The second housing 150 is configured to be coupled to housing 110. The second housing 150 is configured to surround a second portion 204 of workpiece 200. An expandable medium 120 is disposed within the second internal volume 152 between the second housing 150 and the second portion 204 of workpiece 200. Although in Figure 1 and Figure 10 An example of a system 100 comprising two housings (e.g., housing 110 and second housing 150) is shown, but in other examples, system 100 may include any number of housings arranged and connected together in various configurations to accommodate a variety of sizes and shapes of different workpieces.

[0051] In one or more examples, a portion of housing 110 and a second portion of housing 150 are removable to establish communication between internal volumes 112 and 152. As an example, one of the sides 118 of housing 110 and one of the second sides 158 of housing 150 can be removed, and the now-open sides of housing 110 and housing 150 can be engaged to combine internal volumes 112 and 152, thereby increasing the total processing volume of system 100 to accommodate workpieces 200 of different sizes and shapes. In these examples, housing 110 and housing 150 are joined or secured together using any suitable mechanism or technique, such as fastener 138.

[0052] like Figure 1 , Figure 13 and Figure 14As shown, in one or more examples, system 100 includes casting 134. Casting 134 is configured to be applied and hardened over expandable medium 120 and at least a portion 202 of workpiece 200. Casting 134 and a portion of housing 110 form an internal volume 112. Expandable medium 120 is disposed within internal volume 112 between casting 134 and at least a portion 202 of workpiece 200. Casting 134 is configured to harden to surround at least a portion of workpiece 200. In one or more examples, expandable medium 120 is configured to expand such that expandable medium 120 applies a positive pressure 102 to workpiece 200 and casting 134. In one or more examples, casting 134 is placed or disposed between the surfaces of expandable medium 120 and at least a portion 202 of the workpiece 200 being processed. In these examples, casting 134 provides a pressure equalization mechanism or layer during hardening to transfer potentially non-uniform pressure from the expanding expandable medium 120 into substantially uniform pressure against the workpiece 200, which helps improve processing and surface quality and / or helps improve consolidation. In these examples, the expansion of the expandable medium 120 applies or exerts a positive pressure 102 on the exterior of casting 134 and on the workpiece 200 via (e.g., through) casting 134 (e.g., indirectly). In one or more examples, casting 134 is placed or disposed over at least a portion 202 of the expandable medium 120 and the manufactured workpiece 200. In these examples, casting 134 forms at least a portion of the internal volume 112. In these examples, during hardening, casting 134 functions as a space-constrained container, wherein the hardened casting shell serves as the container wall. As an example, casting 134 may serve as part of a cover 116 and / or a side 118. In these examples, the expansion of the expandable medium 120 exerts or applies positive pressure on the interior of the casting 134 and (e.g., directly) on the workpiece 200. In one or more examples, the system 100 includes more than one layer of castings 134, such as a first casting or outer casting and a second casting or inner casting. The inner casting is placed or disposed between the expandable medium 120 and the workpiece 200 and provides a pressure equalization mechanism or layer upon hardening to transfer potentially non-uniform pressure from the expanding expandable medium 120 into substantially uniform pressure against the workpiece 200. The outer casting is placed or disposed above the inner casting, the expandable medium 120, and at least a portion 202 of the workpiece 200 and serves as part of a space-constraining container upon hardening, wherein the hardened outer casting shell serves as a container wall.

[0053] like Figure 1 , Figure 15 and Figure 16As shown, in one or more examples, system 100 includes a cover 136. The cover 136 is configured to cover at least a portion 202 of the expandable medium 120 and the workpiece 200 and is coupled to the housing 110. The cover 136 and a portion of the housing 110 form an internal volume 112. The expandable medium 120 is disposed within the internal volume 112 between the cover 136 and at least a portion 202 of the workpiece 200. In one or more examples, the cover 136 forms or defines at least a portion of the internal volume 112. In one or more examples, the cover 136 replaces the cover 116 and / or serves as a portion of the workpiece 200 corresponding to its cross-sectional shape or profile as a space-constraining container. In these examples, the expandable medium 120 is disposed within the internal volume 112 formed by the cover 136 and between the cover 136 and the workpiece 200. In one or more examples, at least a portion of the cover 136 is flexible and non-expandable. The use of the cover 136 allows for the spatially confined container to be formed over the contour shape of the workpiece 200 and / or the expandable medium 120 (e.g., a closer fit) before the expandable medium 120 expands. In these examples, at least a portion of the cover 136 can be made of any suitable material, including but not limited to metal mesh (e.g., chain linker), ceramic mesh, polymer mesh, etc. In these examples, the cover 136 constrains the expandable medium 120 and responds to the positive pressure 102 generated by the expandable medium 120 during expansion. In these examples, the cover 136 is able to withstand the pressure generated during the expansion of the expandable medium 120.

[0054] like Figure 1 , Figure 17 and Figure 18As shown, in one or more examples, system 100 includes encapsulation element 122. Encapsulation element 122 is configured to surround at least a portion (e.g., a certain amount) of expandable medium 120. Encapsulation element 122 is disposed within internal volume 112 between housing 110 and at least a portion 202 of workpiece 200. In one or more examples, at least some portions of expandable medium 120 are disposed within encapsulation element 122. In one or more examples, expandable granules are disposed in or contained within encapsulation element 122. In one or more examples, encapsulation element 122 surrounds expandable medium 120 (e.g., expandable granules) to better facilitate the handling of expandable medium 120 and its removal after handling. Encapsulation element 122 can take any suitable form, such as an encapsulating film, sealing material layer, bag, bladder, etc. In one or more examples, encapsulation element 122 is non-expandable. In one or more examples, encapsulation element 122 is expandable. In one or more examples, the encapsulation element 122 is made of braided nylon or polyester fabric (e.g., fire hose material).

[0055] In one or more examples, system 100 includes an activation element 124. The activation element 124 is configured to initiate at least one of the expansion and / or contraction of the expandable medium 120 in the internal volume 112. The type or composition of the activation element 124, or the mechanism used by the activation element 124, may vary depending on the type or composition of the expandable medium 120. In one or more examples, the activation element 124 is a chemical, water, a heater, etc.

[0056] like Figure 1 and Figure 19As shown, in one or more examples, system 100 includes at least one volume-changing element 192. The volume-changing element 192 is configured to expand and / or contract within an internal volume 112 to selectively control or alter the internal volume 112 and / or selectively increase and / or decrease the pressure 104 within the housing 110. The volume-changing element 192 can have any feasible cross-sectional shape, such as circular, elliptical, polygonal, etc. The volume-changing element 192 can extend along at least one axis. In one or more examples, the volume-changing element 192 is an intermediate layer within the internal volume 112 of the housing 110. In one or more examples, the volume-changing element 192 comprises a bladder or other expandable element or takes the form of a bladder or other expandable element. In one or more examples, the volume-changing element 192 is filled with a fluid (e.g., gas or liquid) and is configured to uniformly apply a positive pressure 102 to the workpiece 200, such that the positive pressure 102 is applied more evenly. The volume-changing element 192 can be selected to be heat-resistant and easily removed after the workpiece 200 is manufactured. In one or more examples, the volume change element 192 is an expandable element or other volume-changing component of system 100 configured to selectively expand and / or contract to selectively decrease or increase the internal volume 112 of the housing 110, which can be filled by the expandable medium 120, during the expansion of the expandable medium 120. In one or more examples, the volume change element 192 comprises or takes the form of an enclosed bladder or sac having some type of expandable material (e.g., expandable medium 120). In one or more examples, a chemical (e.g., baking soda powder) may be loaded within the volume change element 192. After heating the chemical and generating gas, the volume change element 192 will expand and decrease the fillable volume (internal volume 112) of the housing 110 and / or apply additional positive pressure 102 in a confined space. In other examples, the volume change element 192 is an example of one of different types of expandable medium 120 (e.g., encapsulation element 122). In one or more examples, the volume change element 192 takes the form of or is used as a reinforcing element, which is placed within the internal volume 112 of the housing 110 together with the expandable medium 120 and the workpiece 200. In one or more examples, the volume change element 192 is another type of expandable medium 120 or a different type of expandable material. In one or more examples, the volume change element 192 can be selectively expanded to increase or enhance the pressure applied to the workpiece 200 at one or more locations. As an example, the volume change element 192 can be positioned near (e.g., in or near) a predetermined location or region of the workpiece 200, such as a cavity or contour between different parts of the workpiece 200, such that an enhanced pressure is applied to the radius of the contour during manufacturing (e.g., curing and / or bonding).

[0057] like Figure 1 and Figure 19 As shown, in one or more examples, system 100 includes at least one volume-invariant element 194. The volume-invariant element 194 is configured to maintain a constant size and volume to fill a portion of the internal volume 112. The volume-invariant element 194 may have any feasible cross-sectional shape (e.g., circular, elliptical, polygonal, etc.). The volume-invariant element 194 may extend along at least one axis.

[0058] like Figure 1 As shown, in one or more examples, system 100 includes a pad 196. The pad 196 is disposed within an internal volume 112 between at least a portion of the expandable medium 120 and the workpiece 200. In one or more examples, the pad 196 is positioned between the expandable medium 120 and the workpiece 200. In these examples, the pad 196 helps improve the consolidation of the workpiece 200 and improves surface condition. The pad 196 may be selected to be heat-resistant and easily removable after the workpiece 200 is manufactured. Examples of materials used for the pad 196 include rigid or semi-rigid materials, metallic materials, composite materials, etc. In one or more examples, the pad 196 includes or is formed of multiple pad segments. In these examples, each pad segment is spaced apart from another and is movable relative to adjacent pad segments (e.g., capable of displacement or sliding). In one or more examples, the ends of adjacent pad portions overlap. The separated pad segments of the pad 196 help improve consolidation and surface condition.

[0059] like Figure 1 As shown, in one or more examples, system 100 includes a tooling bag 198. The tooling bag 198 is disposed above at least a portion of workpiece 200. In one or more examples, the tooling bag 198 includes or takes the form of a vacuum tooling bag, a vacuum-laminated tooling bag, or other sheet material, which uses atmospheric pressure to clamp and hold components of workpiece 200 in place below the tooling bag 198 during manufacturing processes.

[0060] like Figure 1 , Figures 3 to 5 and Figure 10As shown, in one or more examples, system 100 includes at least one fastener 138. Fastener 138 is configured to secure base 114 and cover 116 together. Fastener 138 is configured to retain housing 110 in a closed configuration. As an example, fastener 138 is configured to hold cover 116 against base 114 during manufacturing processes, or otherwise secure base 114 and cover 116 together, after workpiece 200 and expandable medium 120 have been loaded into the internal volume 112 of housing 110. Fastener 138 includes any suitable mechanism capable of securing housing 110 in the closed configuration. In one or more examples, fastener 138 includes at least one clamp configured to fasten or secure cover 116 in place relative to base 114 or side 118. The clamps may include any suitable type of clamping and fastening device, such as, but not limited to, mechanical clamps, magnetic clamps, pneumatic clamps, spring clamps, latches, pins, fasteners, counterweights, etc. Fasteners 138 may include any number of clamps.

[0061] like Figure 1 As shown, in one or more examples, system 100 includes at least one pressure sensor 162. Pressure sensor 162 is configured to detect pressure 104 within internal volume 112. In one or more examples, pressure sensor 162 helps monitor the pressure 104 within internal volume 112 within housing 110, and thus helps monitor the positive pressure 102 or omnidirectional force applied to workpiece 200 by expandable medium 120 during and after expansion. In one or more examples, pressure sensor 162 also functions as a fault protection device to limit pressure 104 within housing 110. In one or more examples, pressure sensor 162 generates an indication (e.g., an alarm) when pressure 104 within internal volume 112 exceeds a predetermined threshold. In one or more examples, pressure sensor 162 provides real-time pressure detection and fault protection functionality. In one or more examples, if the detected pressure value (e.g., magnitude) is higher than the alarm or threshold pressure, system 100 is configured to initiate automatic shutdown and other safety measures (e.g., forced air cooling, releasing internal pressure, and opening housing 110). In these examples, pressure sensor 162 may include any suitable type or number of sensors, such as, but not limited to, pressure sensors, load sensors, strain gauges, other sensor devices, and combinations thereof.

[0062] like Figure 1As shown, in one or more examples, system 100 includes at least one shear pin 164. Shear pin 164 is configured to fail when the pressure 104 within the internal volume 112 exceeds a predetermined threshold. In one or more examples, shear pin 164 includes or takes the form of a fail-safe mechanism configured to prevent overpressurization and / or regulation of the pressure within the internal volume 112 of housing 110. As an example, shear pin 164 is used to engage a cover 116 in a closed position to base 114, or to engage multiple sections or portions of housing 110 together. In one or more examples, shear pin 164 is configured to fail at a predetermined pressure greater than the pressure required or desired by the manufacturing process, thereby releasing pressure within housing 110. In one or more examples, shear pin 164 is a sacrificial pin with a known failure strength (corresponding to the maximum permissible internal pressure for alarm). In these examples, if shear pin 164 breaks, system 100 will enter an alarm mode. In other examples, system 100 includes multi-layered safety controls.

[0063] In one or more examples, fastener 138, pressure sensor 162, and / or shear pin 164 are integrated into a single component. As an example, shear pin 164 can be used as fastener 138 to secure housing 110 in a closed position (e.g., holding base 114 and cover 116 together). Optionally, pressure sensor 162 can be used to detect pressure 104 or load on fastener 138 and / or shear pin 164.

[0064] like Figure 1 As shown, in one or more examples, system 100 includes at least one temperature sensor 166. Temperature sensor 166 is configured to detect the temperature of at least one of expandable medium 120, workpiece 200, and internal volume 112.

[0065] like Figure 1As shown, in one or more examples, system 100 includes heater 142. Heater 142 is in thermal communication with expandable medium 120. In one or more examples, heater 142 is configured to heat expandable medium 120 to an activation temperature at which expandable medium 120 expands within internal volume 112 to apply positive pressure 102 to workpiece 200. In one or more examples, heater 142 is configured to heat workpiece 200 to a desired processing (e.g., curing or bonding) temperature. In one or more examples, heater 142 is an internal heater and is configured to be disposed within internal volume 112 of housing 110 together with expandable medium 120. In one or more examples, heater 142 is an external heater and is configured to be disposed outside housing 110. In one or more examples, heater 142 is integrated into housing 110 and / or expandable medium 120, for example, using a smart sensor heating element. Heater 142 can take any suitable form or include any suitable heating device. In various examples where the expandable medium 120 is thermally activated to expand, the housing 110 may be heated from the outside. Alternatively or additionally, the system 100 may include one or more heat-generating substances configured to heat the expandable medium 120 to a predetermined temperature at which the expandable medium 120 will expand.

[0066] like Figure 1 As shown, in one or more examples, system 100 includes at least one battery 144. Battery 144 is configured to store electrical energy. In one or more examples, battery 144 provides power to any electrical components or parts of system 100, enabling system 100 to be utilized in locations where there is no readily available power or infrastructure.

[0067] like Figure 1 As shown, in one or more examples, system 100 includes at least one solar collector 146. Solar collector 146 is configured to generate electricity. In one or more examples, a solar collector 146 is configured to charge battery 144. In one or more examples, a solar collector 146 provides power to any electrical components or parts of system 100, enabling system 100 to be used in locations where there is no readily available electricity or infrastructure.

[0068] In one or more examples, at least a portion of the housing 110 is heat-reflective. In one or more examples, at least one of the side 118, the cover 116, and / or the base 114 is heat-reflective. In one or more examples, at least a portion of the inner surface of the housing 110 comprises or is coated with a heat-reflective material. Heat reflectivity helps improve the heating of the expandable medium 120 to activate its expansion during manufacturing processes.

[0069] like Figure 1 As shown, in one or more examples, system 100 includes controller 170. In one or more examples, controller 170 receives input signals or data from pressure sensor 162, temperature sensor 166, heater 142 and / or other sensors, enabling it to monitor pressure 104 and / or temperature 106 within housing 110, and subsequently increase or decrease as needed to achieve and / or maintain a desired magnitude of positive pressure 102 applied to workpiece 200 by expansion of expandable medium 120.

[0070] In one or more examples, controller 170 includes or takes the form of a closed-loop controller, or otherwise utilizes closed-loop control of pressure 104 and / or temperature 106 within housing 110 and / or applied to workpiece 200 during processing operations. In one or more examples, controller 170 uses real-time pressure measurements from pressure sensor 162 and / or temperature sensor 166 to control or regulate pressure 104 and / or temperature 106 within housing 110 and / or applied to workpiece 200.

[0071] In one or more examples, controller 170 includes a computer or other data processing system, including processor 174, memory 176, and program code 178 stored in memory 176 and executable by processor 174. In one or more examples, controller 170 generates operating instructions or commands and provides these instructions or commands to functional components of system 100. In one or more examples, controller 170 accepts user commands from an operator. In one or more examples, system 100 includes a communication module 172. Communication module 172 communicates with processor 174 and / or forms part of controller 170. Communication module 172 is configured to transmit data representing conditions within internal volume 112, such as at least one of pressure 104 and temperature 106 within internal volume 112. In these examples, data representing the conditions of the manufacturing process can be displayed by controller 170 to the operator.

[0072] In one or more examples, the expandable medium 120 is in an unexpanded state before processing (e.g., Figure 3 , Figure 4 , Figure 11 , Figure 13 , Figure 15 and Figure 17 In its unexpanded (e.g., pre-expanded) state, the expandable medium 120 may be referred to as unexpanded or unexpanded element. During the manufacturing process, the expandable medium 120 is expanded to an expanded state (e.g., Figure 5 , Figures 8 to 10 , Figure 12 , Figure 14 , Figure 16 , Figure 18 and Figure 19 In its expanded state, the expandable medium 120 may be referred to as an expansion or expansion element. In one or more examples, in its expanded state, the expandable medium 120 applies pressure to the inner surface of the housing and the surface of a portion 202 of the workpiece 200. In one or more examples, the expanded expandable medium 120 applies a positive pressure 102 (generated by the expansion of the expandable medium 120) to the workpiece 200 during some or all of the manufacturing processes to facilitate compression. In one or more examples, after the workpiece 200 has been engaged, the expandable medium 120 may be removed from the housing 110 before, simultaneously with, or after the current manufacturing state of removing the workpiece 200 from the housing 110.

[0073] In one or more examples, the expandable medium 120 is configured to expand to an expansion volume 126 in response to a first predetermined change in property 129 of the expandable medium 120. During expansion, the expandable medium 120 applies or exerts a positive pressure 102 on the workpiece 200 and the housing 110. Typically, the expansion volume 126 is known or can be calculated based on the material composition of the expandable medium 120, property 129, and / or the activation temperature of the expandable medium 120. In one or more examples, the expansion volume 126 of the expandable medium 120 in the expanded state is greater than the internal volume 112 of the housing 110. For the purposes of this disclosure, the internal volume 112 refers to the actual usable, fillable internal volume of the cavity of the housing 110. In various examples, the expansion volume 126 is substantially the same as or slightly larger than the internal volume 112 defined by the housing 110, the workpiece 200, and other components placed within the housing 110, such that when the expandable medium 120 expands, the expandable medium 120 exerts a positive pressure 102 on the workpiece 200, unless the internal volume 112 can be changed (e.g., by moving the side 118, controlling the volume change element 192, etc.). In one or more examples, the amount (e.g., volume) of the unexpanded expandable medium 120 to be loaded into the internal volume 112 of the housing 110 is determined by testing or modeling to predict the pressure during and after expansion within the confined volume.

[0074] In one or more examples, the expandable medium 120 is configured to shrink to a shrinkage volume 128 in response to a second predetermined change in property 129 of the expandable medium 120. During shrinkage, the expandable medium 120 reduces or removes the positive pressure 102 applied to the workpiece 200 and the housing 110. Typically, the shrinkage volume 128 is known or can be calculated based on the material composition of the expandable medium 120, property 129, and / or the activation temperature of the expandable medium 120. In various examples, the shrinkage volume 128 of the expandable medium 120 is smaller than the expansion volume 126. In one or more examples, the shrinkage volume 128 is smaller than the expansion volume 126 but larger than the unexpanded (e.g., pre-expanded) volume of the expandable medium 120.

[0075] The expandable medium 120 may comprise any one or more of a variety of suitable types of materials or material compositions configured to expand and optionally contract upon activation or in response to changes in at least one instance of property 129. As shown, in one or more examples, the expandable medium 120 comprises expandable granules. In one or more examples, the expandable granules are thermally activated at an activation temperature. In these examples, the expandable granules are configured to expand when the temperature of the expandable granules rises to the activation temperature. In one or more examples, the expandable granules are chemically activated, for example, by applying an activation element 124. In one or more examples, any suitable number of expandable granules may be placed within the internal volume 112 of the housing 110, provided that when expanded they are able to apply a positive pressure 102 sufficient for the desired processing operation to the workpiece 200. The number of expandable granules depends on the size of the internal volume 112. That is, a smaller number of expandable granules may be required where the housing 110 fits more closely around the contour of the workpiece 200. In the various examples, each of the expandable granules may have any suitable size. In one or more examples, the length of the expandable granules is less than about 1 cm. The expandable granules may be substantially uniform in size or may include granules of different sizes. In one or more examples, the expandable medium 120 (such as expandable granules) comprises or takes the form of foamable granules. In one or more examples, the foamable granules are configured to foam when heated to at least a predetermined foaming temperature (e.g., activation temperature). In one or more examples, the foamable granules include foamable materials, such as thermoplastic materials treated with a foaming agent; inflatable balloons; hollow microspheres; metals; any other suitable components configured to expand upon heating, or any combination thereof.

[0076] In one or more examples, the expandable medium 120 releases heat during expansion and / or contraction. In one or more examples, the expandable medium 120 is endothermic during expansion and / or contraction. In these examples, the activation of the expandable medium 120 and the resulting expansion or contraction can be used to control the temperature 106 during manufacturing (e.g., the temperature within the workpiece 200, the expandable medium 120, and / or the housing 110). In one or more examples, the expandable medium 120 neither releases nor absorbs heat during expansion and / or contraction (e.g., it neither releases nor absorbs heat).

[0077] Now for reference Figure 2 By way of example, this disclosure also relates to a method 1000 for manufacturing workpiece 200, also referred to herein as a portable manufacturing method. The following are examples of method 1000 according to this disclosure. In one or more examples, system 100 ( Figure 1 To implement method 1000, examples of method 1000 include multiple elements, steps, operations, or processes. All elements, steps, operations, or processes described or shown in one example are not required in that example. Some or all of the elements, steps, operations, or processes described or shown in one example may be combined with other examples in various ways without needing to include other elements, steps, operations, or processes described in those other examples, even if one or more such combinations are not explicitly described or shown by example herein.

[0078] In one or more examples, method 1000 includes: surrounding at least a portion 202 of workpiece 200 within an internal volume 112 of housing 110. Method 1000 includes: applying an expandable medium 120 1004 between housing 110 and at least a portion 202 of workpiece 200 within the internal volume 112. Method 1000 includes: expanding the expandable medium 120 1018. Method 1000 includes: applying a positive pressure 102 102 to at least a portion 202 of workpiece 200. Method 1000 includes: processing workpiece 200 1030 in response to the applied positive pressure 102.

[0079] In one or more examples, method 1000 includes: changing the internal volume 112 of 1006. The internal volume 112 can be changed by arranging the side portion 118 and / or by utilizing one or more of the volume-changing element 192 and / or a volume-constant element 194.

[0080] In one or more examples, method 1000 includes: applying 1008 casting 134 to at least a portion 202 of workpiece 200 and hardening 1010 casting 134. In one or more examples, casting 134 and a portion of housing 110 form an internal volume 112. In one or more examples, casting 134 is positioned above workpiece 200 between workpiece 200 and expandable medium 120.

[0081] In one or more examples, method 1000 includes: applying a cover 136 1012 to at least a portion 202 of workpiece 200 and attaching the cover 136 1014 to housing 110. In one or more examples, the cover 136 and a portion of housing 110 form an internal volume 112.

[0082] In one or more examples, method 1000 includes: coupling a second housing 150 to housing 110 1016 such that the internal volume 112 of housing 110 and the second internal volume 152 of housing 150 are in volume communication. In these examples, method 1000 includes: surrounding at least a second portion 204 of workpiece 200 1002 within the second internal volume 152 of second housing 150; applying an expandable medium 120 1004 between second housing 150 and at least a second portion 204 of workpiece 200 within the second internal volume 152, causing the expandable medium 120 to expand 1018; applying a positive pressure 1020 to at least a second portion 204 of workpiece 200; and processing workpiece 200 1030 in response to the application of the positive pressure 102.

[0083] In one or more examples, method 1000 includes detecting pressure 104 within the internal volume 112 of 1022. In one or more examples, pressure sensor 162 is used to detect and / or monitor pressure 104.

[0084] In one or more examples, method 1000 includes controlling pressure 104 within the internal volume 112 of 1024. In one or more examples, pressure 104 is controlled by increasing or decreasing the internal volume 112 of housing 110, such as by selectively changing the position of one or more sides 118 of housing 110. In one or more examples, pressure 104 is controlled by selectively expanding or contracting the expandable medium 120 within the internal volume 112. In one or more examples, pressure 104 is controlled by selectively expanding or contracting a volume-changing element 192 also placed within the internal volume 112 and / or by inserting or removing a volume-fixed element 194 within the internal volume 112.

[0085] In one or more examples, the expansion and / or contraction of the expandable medium 120 is selectively controlled. For example, the expandable medium 120 is configured to expand and contract selectively or controllably as a method of controlling the pressure within the housing 110 and / or applied to the workpiece 200 during processing. In various examples, the expansion and / or contraction of the expandable medium 120 can be controlled in any of a variety of ways, such as applying heat or cooling the expandable medium 120.

[0086] In one or more examples, method 1000 includes detecting temperature 106 within internal volume 112 of 1026. In one or more examples, temperature sensor 166 is used to detect and / or monitor temperature 106.

[0087] In one or more examples, method 1000 includes controlling the temperature 106 within the internal volume 112 of 1028. In one or more examples, the temperature 106 can be controlled by using any combination of the exothermic and / or endothermic properties of the heater 142 and / or the expandable medium 120.

[0088] Examples of system 100 and method 1000 utilize expandable materials for composite structural bonding and volume reduction, such as secondary bonding, with or without adhesives, for example, for composite bonding under pressure (e.g., co-bonding), wherein at least one component of the bonded structure is pre-cured. Additionally, examples of system 100 and method 1000 are capable of bonding non-composite materials (e.g., metals, metal alloys, ceramics, polymers, hybrids, metal matrix composites (MMC), ceramic matrix composites (CMC), polymer matrix composites (PMC), etc.) using epoxy adhesives or any polymer adhesive (e.g., thermosetting or thermoplastic).

[0089] In one or more examples, process 1030 includes curing workpiece 200. In one or more examples, process 1030 includes joining workpiece 200. In one or more examples, the joining step includes or takes the form of co-curing workpiece 200. In one or more examples, the joining step includes or takes the form of co-joining workpiece 200. In one or more examples, the joining step includes or takes the form of secondary joining of workpiece 200.

[0090] In one or more examples, system 100 and method 1000 facilitate co-curing to bond workpieces 200 together. In these examples, material 210 of workpiece 200 (e.g., first material 212 and second material 214) comprises an uncured composite material. In one or more examples, the uncured composite material is a thermosetting composite material. In one or more examples, the uncured composite material is a thermoplastic composite material. In one or more examples, co-curing is achieved without an adhesive. As an example, workpiece 200 includes a first wet prepreg crosslayer (e.g., first material 212) and a second wet prepreg crosslayer (e.g., second material 214). In one or more examples, co-curing is achieved within an adhesive (e.g., an adhesive film). As an example, workpiece 200 includes a first wet prepreg crosslayer (e.g., first material 212), a second wet prepreg crosslayer (e.g., second material 214), and an adhesive (e.g., a third material) placed or disposed between the first and second wet prepreg crosslayers. In one or more co-curing examples, the uncured composite material (e.g., a thermosetting composite material) has a curing temperature and a curing pressure. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature, which is up to the curing temperature of the thermosetting composite material. At the activation temperature, the expandable medium is configured to expand such that the positive pressure 102 reaches or at least the curing pressure. In one or more co-curing examples, the uncured composite material (e.g., a thermoplastic composite material) has a consolidation temperature and a consolidation pressure. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature, which is up to the consolidation temperature of the thermoplastic composite material. At the activation temperature, the expandable medium 120 is configured to expand such that the positive pressure 102 reaches the curing pressure.

[0091] In one or more examples, system 100 and method 1000 facilitate co-bonding to join workpieces 200 together. In these examples, at least one of the materials 210 of workpiece 200 (e.g., first material 212) comprises a cured composite material. At least another of the materials 210 of workpiece 200 (e.g., second material 214) comprises an uncured composite material. In one or more examples, the uncured composite material is a thermosetting composite material. In one or more examples, the uncured composite material is a thermoplastic composite material. In one or more examples, co-bonding is achieved using an adhesive (e.g., an adhesive film). As an example, workpiece 200 includes a precured laminate (e.g., first material 212), a wet prepreg crosslayer (e.g., second material 214), and an adhesive (e.g., a third material) placed or disposed between the precured laminate and the wet prepreg crosslayer. In one or more co-bonding examples, the uncured composite material (e.g., a thermosetting composite material) has a curing temperature and a curing pressure. The expandable medium 120 is configured to expand when the expandable medium 120 is raised to an activation temperature that reaches the curing temperature. At the activation temperature, the expandable medium 120 is configured to expand such that the normal pressure 102 reaches the curing pressure. In one or more co-bonding examples, the uncured composite material (e.g., a thermoplastic composite) has a consolidation temperature and a consolidation pressure. The expandable medium 120 is configured to expand when its temperature rises to the activation temperature, which reaches the consolidation temperature. At the activation temperature, the expandable medium is configured to expand such that the normal pressure 102 reaches the consolidation pressure.

[0092] In one or more examples, system 100 and method 1000 facilitate secondary bonding to join workpieces 200 together. In these examples, the material 210 of workpiece 200 (e.g., first material 212 and second material 214) includes any suitable material or combination of materials, such as, but not limited to, metallic materials, metal alloys, ceramic materials, polymeric materials, hybrid materials, metal matrix composites, ceramic matrix composites, polymer matrix composites, etc. In one or more examples, secondary bonding is achieved using an adhesive (such as an adhesive film). As an example, workpiece 200 includes a first pre-cured laminate or material layer (e.g., first material 212), a second pre-cured laminate or material layer (e.g., second material 214), and an adhesive (e.g., a third material) placed or disposed between the first pre-cured laminate or material layer and the second pre-cured laminate or material layer. In one or more examples, the adhesive is placed between the first material 212 and the second material 214. In these examples, system 100 utilizing the adhesive is capable of secondary bonding, co-bonding, or co-curing with the adhesive of the first material 212 and the second material 214. In one or more of the co-curing examples, co-bonding examples, and / or secondary bonding examples, the adhesive has at least one of a curing temperature and a curing pressure. The expandable medium 120 is configured to expand when its temperature rises to an activation temperature, which is up to the curing temperature. At the activation temperature, the expandable medium 120 is configured to expand such that the positive pressure 102 reaches the curing pressure. In one or more examples, the curing temperatures and / or curing pressures of the uncured composite material and the adhesive are at least substantially the same. In one or more examples, the curing temperatures and / or curing pressures of the uncured composite material and the adhesive are different.

[0093] Now for reference Figure 1 and Figures 3 to 20 As an example, this disclosure also relates to a portable manufacturing kit 300. The following are examples of a portable manufacturing kit 300 according to this disclosure. Examples of the portable manufacturing kit 300 include multiple elements, features, and parts. In one or more examples, the portable manufacturing kit 300 is system 100 (… Figure 1 ) implementation or embodiment. In one or more examples, according to method 1000 ( Figure 2 Implement or use the portable manufacturing kit 300. All elements, features, and / or components described or shown in one example are not required in that example. Some or all of the elements, features, and / or components described or shown in one example may be combined with other examples in various ways without the need to include other elements, features, and / or components described in those other examples, even if one or more such combinations are not explicitly described or shown in the examples herein.

[0094] like Figure 1 and Figures 3 to 20 As shown, in one or more examples, the portable manufacturing kit 300 includes a housing 110. The housing 110 includes or forms an internal volume 112. The housing 110 is configured to enclose at least a portion 202 of a workpiece 200 to be manufactured. The portable manufacturing kit 300 includes an expandable medium 120. The expandable medium 120 is configured to be applied within the internal volume 112 between the housing 110 and at least a portion of the workpiece 200. The expandable medium 120 is configured to expand to apply a positive pressure 102 to the at least portion 202 of the workpiece 200 enclosed by the housing 110.

[0095] In one or more examples of the portable manufacturing kit 300, the housing 110 includes a base 114, a cover 116, and a plurality of sides 118 extending between the base 114 and the cover 116. In one or more examples, the base 114, the cover 116, and the sides 118 form an internal volume 112. In one or more examples, at least one of the sides 118 is movable relative to the base 114 and the cover 116 to selectively change the internal volume 112.

[0096] In one or more examples of the portable manufacturing kit 300, at least one of the sides 118 includes an opening 130. The opening 130 is configured to receive at least a portion 202 of the workpiece 200. In one or more examples of the portable manufacturing kit 300, the housing 110 includes a cap 132. The cap 132 is configured to cover the opening 130 and constrain the expandable medium 120 within the internal volume 112. In one or more examples, the cap 132 is configured to conformally place the workpiece 200 in the opening 130.

[0097] In one or more examples, the portable manufacturing kit 300 includes a second housing 150. The second housing 150 includes or forms a second internal volume 152. The second housing 150 is configured to be coupled to housing 110. The second housing 150 is configured to surround a second portion 204 of workpiece 200. In these examples, an expandable medium 120 is configured to be applied in the second internal volume 152 between the second housing 150 and at least the second portion 204 of workpiece 200. The expandable medium 120 is configured to expand to apply a positive pressure 102 to at least the second portion 204 of workpiece 200 surrounded by the second housing 150.

[0098] In one or more examples, the portable manufacturing kit 300 includes a casting 134. The casting 134 is configured to be applied to and hardened on at least a portion 202 of the expandable medium 120 and the workpiece 200. In one or more examples, the portable manufacturing kit 300 includes a cover 136. The cover 136 is configured to cover at least a portion 202 of the expandable medium 120 and the workpiece 200 and is coupled to the housing 110.

[0099] In other examples, the portable manufacturing kit 300 includes any one or more of the various elements, features, and / or components of system 100 or used during the implementation of method 1000. In one or more examples, the portable manufacturing kit 300 also includes forming tool 148, heater 142, battery 144, solar collector 146, encapsulation element 122, volume change element 192, volume constant element 194, pad 196, tooling bag 198, temperature sensor 166, pressure sensor 162, fastener 138, shear pin 164, controller 170, communication module 172, and at least one or any combination of any other suitable elements, features, and / or components.

[0100] For the purposes of this disclosure, the terms "expandable," "expandable," "expansion," and similar terms refer to the ability to be expanded or the potential or capability to increase in size and / or volume. An expandable substance or discrete element may be able to increase in size or volume symmetrically or asymmetrically. In the case where an expandable substance is capable of symmetrical expansion, the substance undergoes substantially equal expansion along each axis. In the case where an expandable substance exhibits asymmetrical expansion, the substance may undergo greater relative expansion along a first axis or both first and second axes than along different axes. In various examples, the expandable medium 120 is configured to expand when a predetermined change occurs in the expandable medium 120. The predetermined change is generally a change in the physical or chemical properties of the expandable medium 120 or a combination thereof, and / or a change in any other suitable property associated with the expansion of the expandable medium 120. Unless otherwise stated, the expansion of the expandable medium 120 refers to an increase in the volume of the expandable medium 120, the surface area of ​​the expandable medium 120, and / or the spatial extent of the expandable medium 120 in one or more dimensions. As an example, the expandable medium 120 can be configured to expand when its temperature rises from a lower temperature (such as ambient temperature) to a predetermined higher temperature (e.g., activation temperature). Therefore, in cases where the manufacture of workpiece 200 involves raising the temperature of workpiece 200, the expandable medium 120 expands within the internal volume 112 during the manufacturing process. During the bonding process, the expandable medium 120 (e.g., during or after expansion) abuts against the interior of housing 110 and abuts against or applies pressure to workpiece 200.

[0101] For the purposes of this disclosure, the terms “shrinkable,” “shrinkable,” “positively shrinkable,” and similar terms refer to the ability to shrink or the potential or ability to reduce size and / or volume. A shrinkable material or discrete element may be able to reduce its size or volume symmetrically or asymmetrically. In the case where a shrinkable material is capable of symmetrical shrinkage, the material undergoes substantially equal shrinkage along each axis. In the case where a shrinkable material exhibits asymmetrical shrinkage, the material may undergo greater relative shrinkage along a first axis or both first and second axes than along different axes. In various examples, the expandable medium 120 is configured to shrink when a predetermined change occurs in the expandable medium 120. The predetermined change is generally a change in the physical or chemical properties of the expandable medium 120 or a combination thereof, and / or a change in any other suitable property associated with the shrinkage of the expandable medium 120. Unless otherwise stated, the shrinkage of the expandable medium 120 refers to a reduction in the volume of the expandable medium 120, the surface area of ​​the expandable medium 120, and / or the spatial extent of the expandable medium 120 in one or more dimensions. As an example, the expandable medium 120 can be configured to decrease in size when the temperature of the expandable medium 120 decreases from a higher temperature to a predetermined lower temperature.

[0102] In one or more examples, the expandable medium 120 is selected such that, when expanding within the internal volume 112 of the housing 110, the expandable medium 120 applies sufficient pressure to effectively compact the material 210 of the workpiece 200 for proper curing or bonding. For some materials 210, an applied pressure of less than one atmosphere may be sufficient for bonding, while other materials 210 may bond more effectively at an applied pressure of one atmosphere or greater. In one or more examples, the expandable medium 120 is selected to apply sufficient pressure such that pressures typically previously required by an autoclave (e.g., 1 to 5 atmospheres) can be applied.

[0103] In one or more examples, the expandable medium 120 comprises one or more different types, kinds, or compositions of expandable materials (e.g., expandable granules of different types or compositions). In these examples, each of the different types of expandable materials is configured to expand and / or contract (e.g., to a predetermined volume) when heated to a predetermined temperature. In one or more examples, the composition of the different types of expandable medium 120 (e.g., expandable granules of different types) can be designed to achieve a desired relationship between the expansion volume of each type and the temperature of each type over time. In one or more examples, the degree of expansion of a given type or composition of expandable medium 120 (e.g., expandable granules), and the force generated by the expansion, can be measured and recorded. Therefore, the formulation of the composition can be varied to obtain the desired degree of expansion and expansion force. In this way, the amount and / or composition of the expandable medium 120 used can be selected such that expansion and / or contraction within a known enclosing volume (e.g., internal volume 112) will exert a desired pressure on the workpiece 200 at one or more stages of the manufacturing process.

[0104] The expandable medium 120 can take any suitable form. In one or more examples, the expandable medium 120 is added to the housing 110, for example, as pellets, beads, granules, powder, or foam. Alternatively or additionally, the expandable medium 120 is added to the housing 110 as discrete portions of a solid or semi-solid, such as a layer of expandable medium 120 that may cover a portion 202 of the workpiece 200. A layer of expandable medium 120 can be added by adding separate instances of encapsulation elements 122 (e.g., bags or pouches) filled with granules, beads, or other smaller portions of the expandable medium 120. Although Figures 3 to 5 and Figures 8 to 19The expandable medium 120 is depicted as a plurality of expandable granules, but this is a representative depiction and should not be considered as limiting the structure or configuration of the expandable medium 120. In various examples, the expandable medium 120 is added to the internal volume 112 of the housing 110 in an unexpanded state. As shown, before and / or during manufacturing processes, the expandable medium 120 is expanded (e.g., its volume increases) to at least partially fill the internal volume 112, such that the expandable medium 120 (in its expanded state) directly or indirectly applies positive pressure 102 to at least some surfaces of the housing 110 (or casting 134 or covering 136) and at least some surfaces of the workpiece 200 (e.g., the outer surface). Thus, the pressure applied by the expandable medium 120 when it expands helps to compress and solidify a portion 202 of the workpiece 200 during processing. In various examples, the expandable medium 120 is configured to expand (e.g., to a predetermined volume and / or pressure) when a predetermined change occurs in the property 129 of the expandable medium 120 (e.g., in an unexpanded state). In one or more examples, the expandable medium 120 is applied (e.g., inserted or added) within the internal volume 112 of the housing 110 in an unexpanded state. When the expandable medium 120 (in an unexpanded state) is within the internal volume 112, a predetermined change occurs in the property 129 of the expandable medium 120 in the unexpanded state. The expandable medium 120 expands in response to the resulting predetermined change. The property 129 of the expandable medium 120 may be a physical and / or chemical property. In one or more examples, the expandable medium 120 is configured to expand in volume when it interacts with water. As an example, the expandable medium 120 is or includes a desiccant, the volume of which may increase when water is absorbed. For example, anhydrous calcium sulfate (hard gypsum) exhibits a volume increase of approximately 61 percent when it absorbs water to form gypsum. In these examples, water can be added directly to the expandable medium 120, for example, by adding liquid water or water vapor to the interior of the housing 110. Alternatively or additionally, water or water vapor can be generated within the housing 110 itself, for example, through a suitable chemical reaction. In one or more examples, a predetermined change in property 129 of the expandable medium 120 includes a change in the temperature of the expandable medium 120 and / or the temperature of one or more portions of the expandable medium 120. Thus, generating a predetermined change in property 129 of the expandable medium 120 may include raising the temperature of the unexpanded expandable element from a lower temperature (such as ambient temperature (e.g., room temperature)) to a predetermined temperature at least greater than the initial temperature or ambient temperature (e.g., a predetermined temperature a few degrees higher than the ambient temperature suitable for generating predetermined expansion of the expandable element). The expandable element then undergoes thermal expansion due to the temperature increase. In one or more examples, the expandable medium 120 is a thermally activated expandable element.In these examples, the thermally activated expandable element is configured to expand when the temperature of the expandable medium 120 rises to at least a predetermined temperature. Alternatively or additionally, the expansion of the expandable medium 120 by heating it to at least a predetermined temperature generates a predetermined pressure against the workpiece 200. Typically, the predetermined pressure is sufficient to fully cure the composite material. In one or more examples, the predetermined change in property 129 of the expandable medium 120 is a combination of two or more properties of the expandable medium 120, such as a ratio or product of quantitative values ​​associated with the properties of the expandable medium 120, such as two materials with different coefficients of thermal expansion. In various examples, the process of manufacturing the workpiece 200 includes generating a predetermined change in property 129 of the expandable medium 120. In one or more examples, the expansion of the expandable medium 120 occurs automatically during the manufacturing process. For example, property 129 may be the temperature of the expandable medium 120, and the heat applied during the manufacturing process generates a predetermined change in the temperature of the expandable medium 120. In other words, the heat applied to the workpiece 200 during the bonding process raises the temperature of the expandable medium 120 to at least a predetermined temperature associated with the desired volume and / or desired volume increase. One or more properties of the expandable medium 120 may be designed such that temperature changes induced in the expandable medium 120 during the manufacture of the workpiece 200 cause the expandable medium 120 to expand by a desired predetermined amount due to thermal expansion. Alternatively or additionally, expanding the expandable medium 120 may require additional steps beyond those required for curing the workpiece 200. As an example, expanding the expandable medium 120 may include applying an electric field, injecting a liquid, gas, and / or another suitable material and / or inducing any other suitable change in the expandable medium 120. In various examples, the expandable medium 120 is thermally expandable and includes any material capable of undergoing expansion when a predetermined temperature is reached. In a particular example, a family of plastic polymers capable of softening when heated are referred to as thermoplastics. When heated above their glass transition temperature but below their melting point, solid thermoplastics soften and become viscous liquids. In this state, thermoplastics can be reformed, and more specifically, expanded. Various types of thermoplastic materials are known, including acrylic polymers, acrylonitrile butadiene styrene (ABS) polymers, nylon polymers, polylactic acid (PLA) polymers, polybenzimidazole polymers, polycarbonate polymers, polyethersulfone (PES) polymers, polyetherimide (PEI) polymers, polyethylene (PE) polymers, polyphenylene ether (PPO) polymers, polyphenylene sulfide (PPS) polymers, polyvinyl chloride (PVC) polymers, polyvinylidene fluoride (PVDF) polymers, and polytetrafluoroethylene (PTFE) polymers, etc. In particular, expandable media 120 comprising acrylonitrile butadiene styrene (ABS) polymers exhibit advantageous physical properties when used in conjunction with the embodiments described herein.In one or more examples, the expandable medium 120 (e.g., expandable pellets) may additionally include a foaming agent. The foaming agent is selected such that, when heated to at least a predetermined temperature, it forms multiple pores, pockets, or voids within the material of the expandable medium 120, thereby increasing the volume of the expandable medium 120. For example, a suitable foaming agent may be an inert gas that permeates into the expandable medium 120 under pressure. As the temperature of the expandable medium 120 increases from ambient temperature or an initial temperature to a predetermined higher temperature, this foaming agent may be configured to expand at multiple locations within the expandable medium 120, and the expanding gas forms pores, pockets, or voids within the pellets. The foaming agent (if present) may be applied to the expandable medium 120 prior to heating. In examples where the expandable medium 120 includes a foaming agent, the foaming agent may be any suitable substance capable of producing the desired degree of expansion. The foaming agent may include physical foaming agents such as chlorofluorocarbons, hydrochlorofluorocarbons, hydrocarbons, or liquid CO2, etc. Alternatively or additionally, the foaming agent may include a chemical foaming agent selected to react with one or more components of the expandable medium 120, such as isocyanates and water for polyurethanes, azodicarbonamide for vinyl groups, hydrazine and other nitrogen-based materials for thermoplastic and elastomeric foams, and sodium bicarbonate for thermoplastic foams. In examples where the expandable medium 120 includes a foaming agent, the foaming agent may include a foaming agent. In these examples, the foaming agent may be selected to form a gas, and the foaming agent may be a material that facilitates foam formation, such as a surfactant. Suitable foaming agents may include sodium lauryl ether sulfate, sodium lauryl ether sulfate (SLES), sodium lauryl sulfate (also known as sodium dodecyl sulfate or SDS), and ammonium lauryl sulfate (ALS), etc. In the process of manufacturing the workpiece 200, the expandable medium 120 is expanded from a non-expanded state to an expanded state. In one or more examples, the expandable medium 120 is configured to expand in response to heat applied during curing or bonding. The expandable medium 120 expands to fill the internal volume 112 of the housing 110, such that the expansion of the expandable medium 120 applies a positive pressure to the workpiece 200. In one or more examples, the expandable medium 120 is configured (e.g., formulated) such that it is at least partially deformable after, during, and / or before expansion. A degree of deformability allows the expandable medium 120 to squeeze into small gaps that would otherwise be present, such as between granules, between granules and the inner surface of the housing 110, and / or between granules and the workpiece 200. Filling such gaps allows the expandable medium 120 to present a substantially smooth surface to the workpiece 200. In various examples, after a portion 202 of the workpiece 200 has been manufactured, the housing 110 can be unsealed or opened as needed, and the expandable medium 120 can be removed.While the expandable medium 120 is generally easy to remove after the workpiece 200 has been manufactured, in some instances, the expandable medium 120 may remain expanded and tightly packed after the workpiece 200 has been processed and cooled, which may tend to hinder removal. In such cases, the expandable medium 120 may be additionally configured in one or more ways to facilitate separation from the workpiece 200 and the housing 110. As an example, the expandable medium 120 may be configured such that its shape and / or size can be changed when needed, making it easier to extract. For example, the expandable medium 120 may be configured to shrink upon cooling, such that after the workpiece 200 has been processed and cooled, the expandable medium 120 shrinks within the internal volume 112, thereby facilitating its removal. In one or more examples, the expandable medium 120 is modified to minimize sintering (self-adhesion) upon heating and expansion. Alternatively or additionally, the expandable medium 120 may be configured to minimize potential adhesion to surfaces, for example, by coating the expandable granules with a suitable agent configured to prevent adhesion and / or facilitate separation. In one or more examples, suitable agents for addition to the expandable medium 120 include lubricants. As an example, a lubricant may be added to the expandable granules to reduce adhesion between the expandable granules before and / or after volume expansion. A suitable lubricant is one that does not interfere with the curing and / or bonding of the workpiece 200 and prevents the expandable granules from substantially adhering to each other, to the housing 110, or to components of the workpiece 200. Suitable lubricants may include liquids, powders, or combinations thereof. When added as a powder, a suitable lubricant may include nanoparticles. Optionally or additionally, a suitable lubricant may include silicon-based materials, fluorinated polymers, or other substantially inert substances. For example, a suitable lubricant may include polytetrafluoroethylene (PTFE) powder, PTFE nanoparticles, silicone, perfluoropolyether (PFPE), perfluoroalkyl ether (PFAE), perfluoropolyalkyl ether (PFPAE), etc. Such a lubricant may be applied to the expandable granules before they are added to the housing 110. Alternatively or additionally, when the expandable granules are disposed within the housing 110, a suitable lubricant may be applied to the expandable granules. Applying a suitable lubricant to at least some of the expandable granules may include mixing the lubricant with multiple granules and / or pouring the lubricant onto multiple granules. Additionally or alternatively, at least a subset of the multiple expandable granules may be coated with a desired lubricant and then mixed with multiple uncoated granules. In one or more examples, the crystallinity and / or semi-crystallinity along the outer surface of the expandable granules may help prevent the granules from sintering together.In one or more examples, at least some of the expandable granules are configured (e.g., through pretreatment) to have crystalline regions along the outer surface of the granules, such that adding the expandable medium 120 includes adding multiple expandable granules with surface regions of increased crystallinity to reduce adhesion between granules before and / or after the volume expansion of the expandable granules. In one or more examples, expandable granules can be used when the outer surface of the granules exhibits high crystallinity (e.g., a high percentage of the volume of the region near the outer surface of each granule is crystalline). Crystallinity can be induced in expandable granules by controlling one or more factors, including the material composition of the granules, the production temperature to which the granules are heated during production, the time the granule temperature is maintained at the production temperature during production, the electric and / or magnetic fields applied during production, the distribution of the foaming agent in the granules, the composition and / or concentration of the foaming agent, etc. The outer surface of the expandable granules can be crystalline before, during, and / or after foaming.

[0105] like Figure 1 and Figure 11 As shown, in one or more examples, system 100 includes additional elements configured to alter or mitigate the pressure exerted by the expandable medium 120, such as, but not limited to, one or more instances of a volume-constant element 194 (e.g., a substantially incompressible element) and / or one or more instances of a volume-changing element 192 (e.g., an expandable and contractible element), which may increase in volume before or during manufacturing and / or decrease in volume after manufacturing.

[0106] For the purposes of this disclosure, the term "hard" refers to a solid, robust, and / or non-expandable state. In some examples, the term "hard" includes rigidity. Similarly, for the purposes of this disclosure, the terms "hardening," "hardening," and similar terms refer to the ability of a casting or casting material to transform from a flexible, moldable, pliable, flowable, conformable, and / or expandable state to a solid, robust, and / or non-expandable state. In some examples, the casting or casting material is also rigid upon hardening.

[0107] In one or more examples, casting 134 comprises casting material. In one or more examples, the casting material is configured to harden upon a predetermined change in the properties of the casting material. As an example, the casting material may harden in response to changes in temperature, time, chemical composition, pressure, or some other property of the material of casting 134. As an example, casting 134 is applied or formed on a portion 202 of workpiece 200 prior to the addition of expandable medium 120. As another example, casting 134 is applied or formed on a portion 202 of workpiece 200 and expandable medium 120 after the addition of expandable medium 120. In one or more examples, casting 134 is configured to harden before or during manufacturing processes. Casting 134 may be selected to be heat-resistant and easily removable after workpiece 200 has hardened. Examples of casting materials include, but are not limited to, gypsum, cement, fiber (e.g., glass fiber) reinforced plastics, polyvinyl chloride, epoxy resin, rubber, thermosetting or thermoplastic resins, composite materials, ceramics, etc. In one or more examples, the casting material is heat-reflective or includes a heat-reflective material, lining, or layer. As an example, casting 134 may include at least one heat-reflective film as one of the layers in the casting. The heat-reflective film may be the innermost layer, intermediate layer, or inner and / or outermost layer of the casting. The heat reflectivity of casting 134 helps to improve the heating of expandable medium 120 to activate the expansion of expandable medium 120 during the manufacturing process.

[0108] Now for reference Figure 21 and 22 The examples of system 100, method 1000, and portable manufacturing kit 300 described herein can be used with aircraft 1200 (such as...). Figure 21 (illustrated in the diagram) and aerospace manufacturing and maintenance methods 1100 (such as...) Figure 22 (as shown in the flowchart) or used in its context. As an example, aircraft 1200 and / or manufacturing and repair method 1100 may include or utilize components, parts or workpieces manufactured or repaired using system 100 or portable manufacturing kit 300 and / or according to method 1000.

[0109] like Figure 21As shown, in one or more examples, aircraft 1200 can be any aerospace vehicle or platform. In one or more examples, aircraft 1200 includes a fuselage 1202 with an interior 1206. Aircraft 1200 includes multiple onboard systems 1204 (e.g., advanced systems). Examples of onboard systems 1204 of aircraft 1200 include a propulsion system 1208, a hydraulic system 1212, an electrical system 1210, and an environmental system 1214. In other examples, onboard systems 1204 also include one or more control systems coupled to the fuselage 1202 of aircraft 1200. In other examples, onboard systems 1204 also include one or more other systems 1216, 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. Aircraft 1200 can have any number of parts or components manufactured or repaired using system 100 or portable manufacturing kit 300 and / or according to method 1000.

[0110] like Figure 22 As shown, during the pre-production phase of aircraft 1200, manufacturing and maintenance methods 1100 include the specification and design 1102 of aircraft 1200 and material procurement 1104. During the production phase of aircraft 1200, the manufacturing of aircraft 1200 components and sub-assemblies 1106 and system integration 1108 occur. Subsequently, aircraft 1200 is certified and delivered 1110 for service 1112. Routine maintenance and repair 1114 includes changes, reconfigurations, refurbishments, etc., of one or more systems of aircraft 1200.

[0111] Figure 22 Each process of the manufacturing and maintenance method 1100 shown may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0112] Examples of the system 100, method 1000, and portable manufacturing kit 300 shown and described herein can be found in... Figure 22This is employed during any or more stages of the manufacturing and repair method 1100 shown in the flowchart. In the example, components of aircraft 1200 may be manufactured using system 100 or portable manufacturing kit 300 and / or according to method 1000 during component and sub-component manufacturing 1106 and / or system integration 1108. Furthermore, when aircraft 1200 is in use 1112, components of aircraft 1200 may be manufactured and / or repaired using system 100 or portable manufacturing kit 300 and / or according to method 1000. Additionally, during system integration 1108 and certification and delivery 1110, components of aircraft 1200 may be manufactured and / or repaired using system 100 or portable manufacturing kit 300 and / or according to method 1000. Similarly, during maintenance and repair 1114, components of aircraft 1200 may be manufactured and / or repaired using system 100 or portable manufacturing kit 300 and / or according to method 1000.

[0113] The foregoing detailed description refers to the accompanying drawings, which illustrate specific examples described in this disclosure. Other examples with different structures and operations do not depart from the scope of this disclosure. In different drawings, the same reference numerals may refer to the same features, elements, or components. Throughout this disclosure, any one of a plurality of items may be referred to individually as an item, and a plurality of items may be referred to collectively as an item and may be referred to by the same reference numerals. Furthermore, as used herein, a feature, element, component, or step preceding the word "a" or "an" should be understood to not exclude a plurality of features, elements, components, or steps unless such exclusion is expressly stated.

[0114] The foregoing provides illustrative, non-exhaustive examples that may, but do not necessarily, claim protection for the subject matter according to this disclosure. Reference to “example” herein means that one or more features, structures, elements, components, characteristics, and / or operational steps described in connection with the example are included in at least one aspect, embodiment, and / or implementation of the subject matter according to this disclosure. Therefore, the phrases “example,” “another example,” “one or more examples,” and similar language throughout this disclosure may, but do not necessarily, refer to the same example. Furthermore, the subject matter characterizing any example may, but does not necessarily include the subject matter characterizing any other example. Moreover, the subject matter characterizing any example may, but does not necessarily, combine with the subject matter characterizing any other example.

[0115] As used herein, a system, apparatus, device, structure, article, element, component, or hardware "constructed" to perform a specified function is indeed capable of performing the specified function without any changes, and not merely has the potential to perform the specified function after further modification. In other words, a system, apparatus, structure, article, element, component, or hardware "constructed" to perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed for performing the specified function. As used herein, "constructed" means the existing characteristics of the system, apparatus, structure, article, element, component, or hardware that enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For the purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as "constructed" to perform a particular function may additionally or alternatively be described as "suitable" and / or "operable to" perform that function.

[0116] Unless otherwise stated, the terms “first,” “second,” “third,” etc., are used merely as labels in this document and are not intended to impose any order, position, or hierarchy on the items referred to by these terms. Furthermore, references to an item such as “second” do not require or exclude the existence of an item such as “first” or a lower-numbered item and / or an item such as “third” or a higher-numbered item.

[0117] As used herein, when used with a list of items, the phrase “at least one of” means that different combinations of one or more of the listed items may be used, and it may be necessary to use only one of each item in the list. For example, “at least one of item A, item B, and item C” may include, but is not limited to, item A or items A and B. This example may also include items A, B, and C, or items B and C. In other examples, “at least one” may be, for example, but not limited to, two of items A, one of items B, and ten of items C; four items B, seven items C; and other suitable combinations. As used herein, the terms “and / or” and the “ / ” symbol include any and all combinations of one or more associated listed items.

[0118] For the purposes of this disclosure, the terms "connection," "joining," and similar terms refer to two or more elements that are engaged, linked, fastened, attached, connected, communicated, or otherwise associated with each other (e.g., mechanically, electrically, fluidly, optically, electromagnetically). 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 not all associations between the various disclosed elements are necessarily represented. Therefore, connectors other than those depicted in the figures may also exist.

[0119] As used herein, the term "approximately" means or indicates a state that is close to but not exactly close to the stated state, which still performs the desired function or achieves the desired result. As an example, the term "approximately" means a state within an acceptable predetermined tolerance or accuracy, such as within 10% of the stated state. However, the term "approximately" does not exclude a state that is exactly the stated state. As used herein, the term "substantially" means a state that substantially performs the desired function or achieves the desired result.

[0120] The above-mentioned Figure 1 and Figures 3 to 21 It may represent its functional elements, features, or components, and does not necessarily imply any specific structure. Therefore, the illustrated structure may be modified, added to, and / or omitted. Furthermore, those skilled in the art will understand that it is not limited to the structures mentioned above. Figure 1 and Figures 3 to 21 All elements, features, and / or components described and illustrated herein need to be included in each example, and not all elements, features, and / or components described herein need to be depicted in every illustrative example. Therefore, in Figure 1 and Figures 3 to 21 Some of the elements, features, and / or components described and shown herein can be combined in various ways without needing to be included. Figure 1 and Figures 3 to 21 Other features described and illustrated in the accompanying drawings and / or disclosures, even if one or more such combinations are not expressly shown herein. Similarly, additional features, not limited to the examples presented, may be combined with some or all of the features shown and described herein. Unless otherwise expressly stated, the above references to [the document] are subject to change. Figure 1 and Figures 3 to 21 The schematic diagrams depicted are not intended to imply structural limitations regarding the exemplary examples. Rather, while an exemplary structure is shown, it should be understood that this structure can be modified as appropriate. Therefore, modifications, additions, and / or omissions can be made to the illustrated structure. Furthermore, elements, features, and / or components used for similar or at least substantially similar purposes may be omitted. Figure 1 and Figures 3 to 21 Each of the elements is labeled with the same number and may be disregarded in this document. Figure 1 and Figures 3 to 21 Each of these elements, features, and / or components is discussed in detail. Similarly, not all elements, features, and / or components are discussed in detail. Figure 1 and Figures 3 to 21 Each element is labeled, but for consistency, this document may use the associated figure labels.

[0121] The above-mentioned Figure 2 and Figure 22In this document, boxes may represent operations, steps, and / or parts thereof, and the lines connecting the various boxes do not imply any particular order or dependency between the operations or their parts. It should be understood that this does not necessarily represent all dependencies between the various operations disclosed. Figure 2 and Figure 22 The accompanying disclosures describing the operations of the methods set forth herein should not be construed as requiring a specific order of operations to be performed. Rather, while an illustrative order is indicated, it should be understood that the order of operations can be modified where appropriate. Therefore, the operations shown can be modified, added to, and / or omitted, and some operations can be performed in a different order or simultaneously. Furthermore, those skilled in the art will understand that not all described operations need to be performed.

[0122] This application involves the following provisions:

[0123] 1. A system for portable manufacturing, the system comprising:

[0124] A housing, the housing including an internal volume and configured to enclose at least a portion of the workpiece to be manufactured; and

[0125] An expandable medium is disposed within the internal volume between the housing and at least a portion of the workpiece, wherein the expandable medium is configured to expand within the housing such that it applies a positive pressure to the at least a portion of the workpiece surrounded by the housing.

[0126] 2. The system according to Clause 1, wherein at least a portion of the housing is one of the following:

[0127] Rigid;

[0128] Flexible and non-expandable; and

[0129] Flexible and expandable.

[0130] 3. The system according to Clause 1, wherein:

[0131] The housing also includes:

[0132] Base;

[0133] Cover; and

[0134] Multiple sides extending between the base and the cover;

[0135] The base, the cover, and the plurality of sides form the internal volume;

[0136] The cover is movable relative to the base between an open state and a closed state; and

[0137] The housing includes fasteners configured to secure the base and the cover.

[0138] 4. The system according to Clause 3, wherein:

[0139] At least one of the plurality of sides includes an opening;

[0140] The opening is configured to receive at least a portion of the workpiece;

[0141] The housing also includes a cap configured to cover the opening and confine the expandable medium within the internal volume; and

[0142] The cap is configured to conform to the workpiece placed in the opening.

[0143] 5. The system according to Clause 3, wherein at least one of the plurality of sides is movable relative to the base and the cover to selectively change the internal volume.

[0144] 6. The system according to Clause 3, further comprising: a second housing, the second housing including a second internal volume, and configured to be coupled to the housing and surround a second portion of the workpiece.

[0145] in:

[0146] The expandable medium is further disposed within the second internal volume between the second housing and the second portion of the workpiece; and

[0147] A portion of the housing and a second portion of the second housing are removable to allow the internal volume and the second internal volume to be placed in communication.

[0148] 7. The system according to Clause 1, further comprising at least one of the following:

[0149] A casting configured to be applied to and hardened over at least a portion of the expandable medium and the workpiece, wherein the casting and a portion of the housing form the internal volume, and the expandable medium is disposed within the internal volume between the casting and at least a portion of the workpiece;

[0150] A cover configured to cover at least a portion of the expandable medium and the workpiece and coupled to the housing, wherein the cover and a portion of the housing form the internal volume, and the expandable medium is disposed within the internal volume between the cover and the at least a portion of the workpiece;

[0151] A forming tool configured to be placed within the internal volume and to support at least a portion of the workpiece;

[0152] An encapsulation element configured to surround at least a portion of the expandable medium, wherein the encapsulation element is disposed within the internal volume between the housing and the at least a portion of the workpiece;

[0153] A volume-changing element, wherein the volume-changing element is disposed within the internal volume between the housing and at least a portion of the workpiece;

[0154] A volume-invariant element, wherein the volume-invariant element is disposed within the internal volume between the housing and at least a portion of the workpiece;

[0155] A pad, wherein the pad is disposed within the internal volume between the expandable medium and at least a portion of the workpiece; and

[0156] A tooling bag, which is disposed above at least a portion of the workpiece.

[0157] 8. The system according to Clause 1, further comprising an activation element configured to initiate the expansion or contraction of the expandable medium in the internal volume.

[0158] 9. The system according to Clause 1, further comprising at least one of the following:

[0159] A pressure sensor configured to detect pressure within the internal volume;

[0160] A shear pin, the shear pin being configured to fail when the pressure within the internal volume exceeds a predetermined threshold;

[0161] A heater, the heater being in thermal communication with the expandable medium, wherein at least a portion of the housing is heat-reflective;

[0162] A temperature sensor configured to detect the temperature of at least one of the expandable medium, the workpiece, and the internal volume;

[0163] A battery configured to store electrical energy;

[0164] A solar collector, configured to generate electricity; and

[0165] A communication module configured to transmit data indicating the condition of at least one of pressure and temperature within the internal volume.

[0166] 10. The system according to Clause 1, wherein:

[0167] The expandable medium is configured to expand to an expanded volume in response to a first predetermined change in the properties of the expandable medium; and

[0168] The expandable medium is configured to shrink to a shrinkage volume in response to a second predetermined change in the properties of the expandable medium.

[0169] 11. The system according to Clause 1, wherein the expandable medium is one of the following:

[0170] It releases heat during expansion; and

[0171] It absorbs heat during expansion.

[0172] 12. A method for manufacturing a workpiece, the method comprising:

[0173] At least a portion of the workpiece is enclosed within the internal volume of the housing;

[0174] An expandable medium is applied within the internal volume between the housing and at least a portion of the workpiece;

[0175] The expandable medium expands;

[0176] Applying a positive pressure to at least a portion of the workpiece; and

[0177] The workpiece is processed in response to the application of the positive pressure.

[0178] 13. The method according to Clause 12, further comprising one of the following steps:

[0179] Change the internal volume;

[0180] A casting is applied over at least a portion of the workpiece and the casting is hardened, such that the casting and a portion of the housing form the internal volume; and

[0181] A cover is applied over at least a portion of the workpiece, and the cover is attached to the housing such that the cover and a portion of the housing form the internal volume.

[0182] 14. The method according to Clause 12, further comprising:

[0183] The second housing is connected to the housing such that the internal volume of the housing and the second internal volume of the second housing are voluminously connected;

[0184] At least a second portion of the workpiece is enclosed within the second internal volume of the second housing;

[0185] The expandable medium is applied in the second internal volume between the second housing and the at least second portion of the workpiece;

[0186] The expandable medium expands;

[0187] Applying the positive pressure to at least the second portion of the workpiece; and

[0188] The workpiece is processed in response to the application of the positive pressure.

[0189] 15. The method according to Clause 12, further comprising at least one of the following steps:

[0190] Detect the pressure within the internal volume;

[0191] Control the pressure within the internal volume;

[0192] Detecting the temperature within the internal volume; and

[0193] Control the temperature within the internal volume.

[0194] 16. The method according to Clause 12, wherein:

[0195] The processing steps include: joining the workpieces and curing one of the workpieces; and

[0196] The bonding steps include one of: co-curing the workpiece, co-bonding the workpiece, and secondary bonding the workpiece.

[0197] 17. A portable manufacturing kit, said portable manufacturing kit comprising:

[0198] A housing, the housing including an internal volume and configured to enclose at least a portion of the workpiece to be manufactured; and

[0199] Expandable media,

[0200] in:

[0201] The expandable medium is configured to be applied within the internal volume between the housing and at least a portion of the workpiece; and

[0202] The expandable medium is configured to expand to apply positive pressure to the at least portion of the workpiece that is surrounded by the housing.

[0203] 18. The portable manufacturing kit as described in Clause 17, wherein:

[0204] The housing also includes:

[0205] Base;

[0206] Cover; and

[0207] Multiple sides extending between the base and the cover;

[0208] The base, the cover, and the plurality of sides form the internal volume; and

[0209] At least one of the plurality of sides is movable relative to the base and the cover to selectively change the internal volume;

[0210] At least one of the plurality of sides includes an opening;

[0211] The opening is configured to receive at least a portion of the workpiece;

[0212] The housing also includes a cap configured to cover the opening and confine the expandable medium within the internal volume; and

[0213] The cap is configured to conform to the workpiece placed in the opening.

[0214] 19. The portable manufacturing kit according to Clause 18, further comprising a second housing having a second internal volume and configured to be coupled to the housing and enclosing a second portion of the workpiece.

[0215] in:

[0216] The expandable medium is further configured to be applied within the second internal volume between the second housing and the at least second portion of the workpiece; and

[0217] The expandable medium is configured to expand to apply the positive pressure to the at least second portion of the workpiece surrounded by the second housing.

[0218] 20. The portable manufacturing kit according to Clause 17, wherein the portable manufacturing kit further comprises at least one of the following:

[0219] A casting configured to be applied to and hardened over the expandable medium and at least a portion of the workpiece;

[0220] A cover, configured to cover at least a portion of the expandable medium and the workpiece, and coupled to the housing;

[0221] A forming tool, the forming tool being configured to be placed in the internal volume and to support at least a portion of the workpiece;

[0222] A tooling bag, the tooling bag being disposed above at least a portion of the workpiece;

[0223] A pad, wherein the pad is disposed in the internal volume between the expandable medium and at least a portion of the workpiece;

[0224] Volume change element;

[0225] Components with constant volume;

[0226] An activation element configured to initiate the expansion or contraction of the expandable medium within the internal volume;

[0227] A packaging element configured to surround the expandable medium;

[0228] A communication module configured to transmit data indicating the condition of at least one of pressure and temperature within the internal volume;

[0229] A heater, wherein the heater is in thermal communication with the expandable medium;

[0230] A pressure sensor configured to detect pressure within the internal volume;

[0231] A temperature sensor configured to detect the temperature of at least one of the expandable medium, the workpiece, and the internal volume;

[0232] A battery, the battery being configured to store electrical energy; and

[0233] A solar collector, which is configured to generate electricity.

[0234] Furthermore, references to features, advantages, or similar language used throughout this specification do not imply that all features and advantages that can be implemented using the examples disclosed herein should be or are not present in any single example. Rather, references to features and advantages are understood to mean that a particular feature, advantage, or characteristic described in connection with an example is included in at least one example. Therefore, discussions of features, advantages, and similar language used throughout this disclosure may, but do not necessarily, refer to the same examples.

[0235] The features, advantages, and characteristics described in one example can be combined in any suitable manner in one or more other examples. Those skilled in the art will recognize that the examples described herein can be practiced without the presence of one or more specific features or advantages in a particular example. In other instances, additional features and advantages that may not be present in all examples may be recognized in certain examples. Furthermore, although various examples of system 100, method 1000, and portable manufacturing kit 300 have been shown and described, modifications will occur to those skilled in the art upon reading the specification. This application includes such modifications and is limited only by the scope of the claims.

Claims

1. A system for portable manufacturing, the system comprising: A housing, the housing having an internal volume and configured to enclose at least a portion of the workpiece to be manufactured; as well as An expandable medium is disposed within the internal volume between the housing and at least a portion of the workpiece, wherein the expandable medium is configured to expand within the housing such that it applies a positive pressure to the at least a portion of the workpiece surrounded by the housing.

2. The system according to claim 1, wherein, At least a portion of the housing is one of the following: Rigid; Flexible and non-expandable; and Flexible and expandable.

3. The system according to claim 1, wherein: The housing also includes: Base; Cover; and Multiple sides extending between the base and the cover; The base, the cover, and the plurality of sides form the internal volume; The cover is movable relative to the base between an open state and a closed state; and The housing includes fasteners configured to secure the base and the cover.

4. The system according to claim 3, wherein: At least one of the plurality of sides includes an opening; The opening is configured to receive at least a portion of the workpiece; The housing also includes a cap configured to cover the opening and confine the expandable medium within the internal volume; and The cap is configured to conform to the workpiece placed in the opening.

5. The system according to claim 3, wherein, At least one of the plurality of sides is movable relative to the base and the cover to selectively change the internal volume.

6. The system according to claim 3, further comprising: A second housing, comprising a second internal volume, and configured to be attached to and surround a second portion of the workpiece. in: The expandable medium is further disposed within the second internal volume between the second housing and the second portion of the workpiece; and A portion of the housing and a second portion of the second housing are removable to allow the internal volume and the second internal volume to be placed in communication.

7. The system of claim 1, further comprising at least one of the following: Castings, said castings being configured to be applied to and hardened over said expandable medium and said workpiece at least a portion thereof, wherein, The casting and a portion of the housing form the internal volume, and the expandable medium is disposed within the internal volume between the casting and at least a portion of the workpiece; A cover configured to cover at least a portion of the expandable medium and the workpiece and coupled to the housing, wherein the cover and a portion of the housing form the internal volume, and the expandable medium is disposed within the internal volume between the cover and the at least a portion of the workpiece; A forming tool configured to be placed within the internal volume and to support at least a portion of the workpiece; An encapsulation element configured to surround at least a portion of the expandable medium, wherein the encapsulation element is disposed within the internal volume between the housing and the at least a portion of the workpiece; A volume-changing element, wherein the volume-changing element is disposed within the internal volume between the housing and at least a portion of the workpiece; A volume-invariant element, wherein the volume-invariant element is disposed within the internal volume between the housing and at least a portion of the workpiece; A pad, wherein the pad is disposed within the internal volume between the expandable medium and at least a portion of the workpiece; and A tooling bag, which is disposed above at least a portion of the workpiece.

8. The system of claim 1, further comprising an activation element configured to initiate the expansion or contraction of the expandable medium in the internal volume.

9. A method for manufacturing a workpiece, the method comprising: At least a portion of the workpiece is enclosed within the internal volume of the housing; An expandable medium is applied within the internal volume between the housing and at least a portion of the workpiece; The expandable medium expands; Apply a positive pressure to at least a portion of the workpiece; as well as The workpiece is processed in response to the application of the positive pressure.

10. A portable manufacturing kit, the portable manufacturing kit comprising: A housing, the housing having an internal volume and configured to enclose at least a portion of the workpiece to be manufactured; as well as Expandable media, in: The expandable medium is configured to be applied within the internal volume between the housing and at least a portion of the workpiece; and The expandable medium is configured to expand to apply positive pressure to the at least portion of the workpiece that is surrounded by the housing.

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