Blind fastener placement in metal parts

Abstract

Methods and systems for the manufacture of metal parts for the placement of blind fasteners. Embodiments include a metal part that comprises at least one of a receptacle or a fastener on at least one surface of the metal part. Some embodiments include forming the metal part via an additive manufacturing process. The metal part may be formed by stacking a plurality of patterned metal sheets and bonding the patterned metal sheets.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of and priority to U.S. Provisional Application No. 63 / 676,602, filed on Jul. 29, 2024, the entire disclosure of which is hereby incorporated by reference as if set forth in its entirety herein.TECHNICAL FIELD

[0002] Embodiments described herein generally relate to methods and apparatus for manufacturing metal parts, and more specifically to the manufacture of metal parts for the placement of blind fasteners.BACKGROUND

[0003] Metal parts, such as heat sinks and cold plates, may be manufactured using a variety of manufacturing processes including forging, machining, and additive processes. For example, a metal part may be assembled via laminated object manufacturing (LOM), which involves assembling complex 3D structures by sequentially depositing layers of material. Each successive layer may be bonded to and / or deposited on the previous layer to gradually assemble the 3D structure.

[0004] In many scenarios, it is desirable for the part to be configured to allow the placement of complementary fasteners such as rivets, anchors, and snap-fit fasteners. Fasteners provide a means for mechanically joining multiple parts or components without the need for welding, adhesives, or other permanent bonding methods. This allows for modular construction and assembly, where parts may be assembled and later disassembled for maintenance, inspection, or replacement. Blind fasteners are particularly useful, as they allow parts to be joined when access is available from only one side. This can be essential in situations where the opposite side is obstructed, enclosed, or otherwise inaccessible during assembly.

[0005] Traditional machining methods, however, often encounter significant limitations when attempting to produce surface features that allow for the placement of fasteners, such as partial enclosures, overhangs, or undercuts. For example, integrating blind fasteners into machined components often necessitates extra steps such as drilling, tapping, or inserting hardware into opposing faces of a metal part. These steps may be labor-intensive and time-consuming, particularly in high-precision or constrained environments.

[0006] Accordingly, a need exists for improved methods of manufacturing metal parts for the placement of blind fasteners.SUMMARY

[0007] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description section. This summary is not intended to identify or exclude key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0008] According to one aspect, the techniques described herein relate to a metal part formed via an additive manufacturing process, the metal part including at least one of a receptacle or a fastener on at least one surface of the metal part.

[0009] In some embodiments, the receptacle or fastener is configured to be secured with access to the surface of the metal part without needing access to an opposite surface of the metal part.

[0010] In some embodiments, the additive manufacturing process includes a laminated object manufacturing process.

[0011] In some embodiments, the receptacle or fastener is configured to interface with a different surface of the metal part.

[0012] In some embodiments, the metal part includes a receptacle and a fastener configured to interface with each other.

[0013] In some embodiments, the metal part is formed from a plurality of patterned metal sheets.

[0014] In some embodiments, at least one dimension of the receptacle or fastener is determined based on at least one dimension of a corresponding receptacle or fastener.

[0015] In some embodiments, the receptacle or fastener is configured to interface with an anchor for mounting a fastener.

[0016] In some embodiments, the receptacle or fastener comprises a plumbed fastener for receiving fluid into the part.

[0017] In some embodiments, the plumbed fastener is sealed against the part using at least one of a gasket, o-ring, or software metal ring.

[0018] According to another aspect, the techniques described herein relate to a metal part formed via an additive manufacturing process, the process including stacking a plurality of patterned metal sheets; and bonding the patterned metal sheets for forming the metal part, the metal part including at least one receptacle on at least one surface of the metal part.

[0019] In some embodiments, the receptacle is configured to be secured with access to the surface of the metal part without needing access to the opposite surface of the metal part.

[0020] In some embodiments, the receptacle includes an external hole and a void within the metal part, the external hole having a cross-sectional area distinct from a cross-sectional area of the void.

[0021] In some embodiments, at least one dimension of the receptacle is determined based on at least one feature of a corresponding fastener.

[0022] In some embodiments, the dimension includes a depth that is at least the insertable length of the corresponding fastener.

[0023] In some embodiments, the receptacle is configured to receive a deformable pin or tube, the pin or tube configured to deform under an overhang region within the receptacle.

[0024] According to another aspect, the techniques described herein relate to a method for forming a metal part via additive manufacturing, the method including stacking a plurality of patterned metal sheets; and bonding the patterned metal sheets for forming the metal part, the metal part including at least one of a receptacle or a fastener on at least one surface of the metal part.

[0025] In some embodiments, the receptacle or fastener is configured to be secured with access to the surface of the metal part without needing access to an opposite surface of the metal part.

[0026] In some embodiments, the receptacle or fastener is configured to interface with a different surface of the metal part.

[0027] In some embodiments, the method further comprises joining the metal part with an additional metal part using the receptacle or fastener; and sealing the receptacle or fastener between the metal part and the additional metal part.BRIEF DESCRIPTION OF DRAWINGS

[0028] Non-limiting and non-exhaustive embodiments of this disclosure are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified:

[0029] FIG. 1 depicts a cross-section of a metal part;

[0030] FIG. 2 depicts a cross-section of another metal part; and

[0031] FIG. 3 is a top-down view of yet another metal part;

[0032] FIG. 4A depicts a cross-section of a blind rivet inserted into multiple metal parts;

[0033] FIG. 4B depicts a cross-section of the rivet of FIG. 4A with the rivet installed;

[0034] FIG. 5 depicts a cross-section of yet another metal part;

[0035] FIG. 6A depicts a cross-section of yet another metal part with a plumbed fastener inserted;

[0036] FIG. 6B depicts an orthogonal view of the metal part of FIG. 6A with the plumbed fastener inserted;

[0037] FIG. 6C depicts a cross-section of the metal part of FIG. 6A with the plumbed fastener inserted and installed; and

[0038] FIG. 6D depicts an orthogonal view of the metal part of FIG. 6A with the plumbed fastener inserted and installed.

[0039] FIG. 7 depicts yet another metal part with a fluid fitting inserted into the part.DETAILED DESCRIPTION

[0040] Various embodiments are described more fully below with reference to the accompanying drawings, which form a part hereof, and which show specific exemplary embodiments. However, the concepts of the present disclosure may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided as part of a thorough and complete disclosure, to fully convey the scope of the concepts, techniques and implementations of the present disclosure to those skilled in the art. Embodiments may be practiced as methods, systems or devices. The following detailed description is, therefore, not to be taken in a limiting sense.

[0041] Reference in the specification to “one embodiment” or to “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least one example implementation or technique in accordance with the present disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0042] In addition, the language used in the specification has been principally selected for readability and instructional purposes and may not have been selected to delineate or circumscribe the disclosed subject matter. Accordingly, the present disclosure is intended to be illustrative, and not limiting, of the scope of the concepts discussed herein.Definitions

[0043] Unless otherwise specified, the following terms as used herein shall have the meanings as provided below:

[0044] The term “laminated object manufacturing” (LOM) refers to a method of manufacturing a part, containing additive and subtractive steps, beginning with contiguous sheets of material, and processing sheets sequentially to form a part.

[0045] The term “bonding” refers to the process through which the contiguous sheets of material are formed into a part. The workpiece is subjected to a combination of heat and applied force which form covalent and / or metallic bonds between the sheets of material, forming an object.

[0046] The term “part” refers to a manufactured object.

[0047] The term “workpiece” refers to a stack of metal sheets to be bonded into at least one part and at least one corresponding support structure.

[0048] The term “metal sheet” refers to a metal sheet or foil that is stacked in a workpiece. In some embodiments, the metal sheet may comprise a core layer and / or a clad layer. In some embodiments, the metal sheet may comprise at least one of titanium, aluminum, copper, magnesium, aluminum alloy, magnesium alloy, and / or titanium alloy.

[0049] The term “sheet” refers generally to a metallic layer between 25 μm to 10 cm in thickness.

[0050] The term “void” refers to a volume cut out of a metal sheet in the support or part region which is fully enclosed.

[0051] The term “fastener” refers to a component configured to join two or more parts together in a secure manner.

[0052] The term “blind fastener” refers to a fastener that is configured to be installed from with only one accessible side of a part.

[0053] The term “receptacle” refers to a component configured to receive or otherwise interface with a corresponding fastener to join two or more parts together.EMBODIMENTS

[0054] In embodiments of this invention, a metal part allowing the placement of blind fasteners may be formed using a suitable manufacturing process such as an additive manufacturing process. The metal part may comprise at least one of a receptacle or a fastener on at least one surface of the metal part. In some embodiments, the receptacle or fastener may be configured to be secured with access to a face of the metal part without needing access to the opposite face of the metal part.

[0055] The embodiments described herein may have various benefits over existing techniques for forming metal parts. As described above, for example, fasteners can significantly increase the versatility and utility of metal parts by allowing modular attachment of multiple parts. In particular, blind fasteners can be installed without the need for access to multiple faces of the part. This may be advantageous in contexts involving complex geometries, enclosed structures, and / or limited assembly place. Directly integrating surface features during the manufacturing process also eliminates the need for secondary machining operations and enables the production of parts that are ready for immediate mechanical integration. This can increase manufacturing efficiency and reduce assembly time.

[0056] Non-limiting examples of these configurations are further discussed below.Part Manufacture

[0057] As described above, metal parts may be formed using a variety of manufacturing processes, such as additive manufacturing processes (e.g., binding jetting, laminated object manufacturing, powder bed fusion, etc.) and / or traditional manufacturing techniques (e.g., machining, casting, stamping, forming, etc.). For example, in LOM, a workpiece consisting of a plurality of metal sheets may be assembled and bonded to form a metal part. The workpiece may be assembled in a laminated fashion with the metal sheets. The metal sheets may be patterned such that the pattern of the metal sheets partitions the workpiece into at least one support region and at least one part region.

[0058] The metal sheets may be bonded using any suitable bonding method, such as solid-state diffusion bonding, semi-solid state diffusion bonding, and / or transient liquid-phase bonding. The metal sheets may be bonded in a heated press, a more complicated bonding machine comprising a heated press and a vacuum chamber, and / or a bonding machine of any configuration appropriate for laminated object manufacturing of metal parts. The metal sheets may be bonded by applying a mechanical force along at least one axial direction of the metal sheets.

[0059] In some embodiments, each metal sheet may have a unique pattern which comprises a cross-sectional slice of the part. The pattern on each metal sheet (e.g., a pattern of void spaces) may be configured to transmit force through the metal sheets.

[0060] In some embodiments, the metal sheets may be patterned so that material is removed from at least one part region of each metal sheet. This may create a pattern of voids within the workpiece. The voids may be formed via any appropriate cutting technique, such as drag knife cutting, laser cutting, and / or etching. The voids may be formed from regular, geometric patterns and / or random distributions within the part. In some embodiments, the pattern of voids may form larger holes or cavities within the part.Part Configurations

[0061] In embodiments of this invention, a metal part may be formed to include at least one surface feature such as a receptacle or a fastener. The surface feature may allow the secure installation of fasteners, such as rivets, anchors, and / or snap-fit fasteners. The fasteners may be blind fasteners configured to be secured with access to a surface of the part without the need for access to the opposite surface of the part.

[0062] At least a portion of the part may be configured to act as a male and / or female component for a particular type of fastener. For example, at least one portion of the part may act as a female component. In some examples, at least one portion of the part may act as a male component. In some examples, at least one portion of the part may act as a female component and at least another portion of the part may act as a male component corresponding the female component.

[0063] In some embodiments, the part may be configured to interface with itself. For example, the part may include a fastener (or any other male component) and a receptacle (or any other corresponding female component). The fastener may be brought into contact with and engaged into the receptacle during a forming process, such as bending, folding, stamping, crimping, and / or rolling. The forming process may occur during or after the assembly of the part (e.g., after the bonding of metal sheets). The forming process may form a semi-permanent or reversible mechanical interlock.

[0064] In some embodiments, the metal part may be formed from multiple materials. For example, the surface feature may be at least partially formed from a material with different properties relative to the rest of the part, such as improved hardness, wear resistance, and / or strength. The material may include at least one of aluminum, titanium, stainless steel, nickel, cobalt-chromium, and / or ceramics. In some embodiments, a cladded sheet may be used, where a core layer of a first material is bonded with at least one clad layer of a second material. The clad layer may be oriented such that it forms at least a portion of the surface feature, such as the walls of a receptacle. For example, a corrosion-resistant material (e.g., aluminum alloy or a titanium-clad layer) may be used to line the walls of a receptacle intended to interface with a fastener.

[0065] In some embodiments, the fastener may be of the same material or composition as the metal part. In some embodiments, the fastener may be of a second material. For example, a stainless steel fastener may be inserted into a receptacle within a copper metal part.

[0066] In some embodiments, the surface features may be insulated or isolated from other regions of the part, such as internal channels and / or electronic components. For example, the part may include insulating layers to insulate the surface features.Receptacles

[0067] In embodiments of this invention, a metal part may be formed to include at least one hole, cavity, or recess for forming a receptacle. For example, metal sheets may be patterned to include a pattern of voids. The voids may form a hole or cavity after the metal sheets are assembled and bonded to form the metal port. The receptacle may be configured to receive a fastener and / or any other suitable feature for joining multiple parts or components. The receptacle may be located on at least one surface of the part.

[0068] In some embodiments, the receptacle may include an external hole that overhangs an internal void within the part. The cross-sectional area of the hole may be distinct from the cross-sectional area of the internal void. For example, the cross-sectional area of the hole may be smaller than the cross-sectional area of the internal void. This may aid the mechanical retention of fasteners that rely on anchoring mechanisms for installation. The geometry of the receptacle may include any suitable geometry, such as a circular, elliptical, rectangular, polygonal, and / or asymmetric geometry. In some embodiments, the geometry of the receptacle may match and / or otherwise correspond to the geometry of a corresponding fastener.

[0069] In some embodiments, the outermost portion of the receptacle corresponding to the cross-sectional area of the hole may have a depth that is the thickness of a single metal sheet or layer. In some embodiments, the depth of the outermost portion may exceed the thickness of a single sheet (e.g., the thickness of multiple sheets), allowing for greater insertion depth or improved engagement with the fastener.

[0070] In some embodiments, the receptacle may include at least two distinct cross-sectional areas. In some embodiments, the receptacle may transition smoothly and / or continuously from one cross-sectional area to another.

[0071] In some embodiments, a cross-sectional area of the receptacle (e.g., the cross-sectional area of the hole) may be at least partially defined by a continuous function, so that the cross-sectional area appears at least partially as a smooth curve.

[0072] In some embodiments, the receptacle may be configured with a textured surface to enhance mechanical retention of a fastener. The textured surface may include at least one of radial grooves, ribs, striations, micro-textures, and / or ridges.

[0073] FIG. 1 illustrates a cross-section of a metal part 101. The metal part 101 may be formed from multiple stacked layers (e.g., multiple metal sheets). As shown, for example, the metal part 101 includes at least four layers, although the metal part 101 may include any suitable number of layers.

[0074] The metal part 101 may include a receptacle 102, as shown by the shaded region. The receptacle 102 may be configured to interface with a corresponding fastener. The receptacle 102 may include at least two distinct cross-sectional areas, with the outermost area 103 being shown. The outermost area 103 may be smaller than an inner cross-sectional area. This may form an internal undercut or cavity that is not externally visible or accessible without passing through the outermost area 103. The outermost area 103 may function as an overhang that is suitable for retaining fasteners and other interfacing components.

[0075] FIG. 2 illustrates a cross-section of another metal part 201. The metal part 201 may include a receptacle 202, as shown by the shaded region. As shown, the receptacle 202 may be formed from twelve layers within the metal part 201. The cross-sectional area of the receptacle 202 may approximate a smooth curve, which may be defined at least partially by a continuous function. The smooth curve of the cross-sectional area may allow for more gradual deformation and engagement of a corresponding fastener.Fasteners

[0076] In embodiments of the invention, the dimensions and / or geometry of a receptacle may be determined based on at least one feature of the corresponding fastener, such as a fastener type, shape, geometry, and / or dimension. For example, the receptacle may have a depth that is at least the insertable length of the fastener. The minimum diameter or cross-sectional dimension of the receptacle may be at least the diameter of the widest portion of the fastener, such as a collar, hat, head, and / or other radial feature of the fastener.

[0077] In some embodiments, the receptacle may be configured to receive an anchor or any other component that serves as a base or mount for the fastener. The geometry of the receptacle may include undercuts, shoulders, or recesses designed to lock or retain the anchor. The anchor may interface with the receptacle during or after the assembly process.

[0078] In some embodiments, the receptacle may be configured to receive a threaded fastener, such as a threaded stud, threaded insert, and / or a threaded stud-and-nut combination. The receptacle may include internal threads, thread-compatible surface texturing, and / or embedded inserts that allow mechanical or frictional engagement with the threaded fastener. In some embodiments, the receptacle may be configured to interface with a component that is coupled to threaded fastener via a secondary fastening action, such as a nut.

[0079] In some embodiments, the receptacle may be configured to receive various types of rivets, such as solid rivets, blind rivets, drive rivets, self-piercing rivets, and / or pop rivets. The receptacle may have a minimum diameter matching at least one component of a rivet, such as the rivet collar or the rivet head. The receptacle may include an undercut or internal void for receiving the rivet. The depth of the receptacle may be at least the combined length of the rivet hat and mandrel head to ensure complete insertion. In some embodiments, the part may include a standing post or protrusion that is formable (e.g., by heat, pressure, or deformation) into a rivet that mechanically joins to another region of the part.

[0080] In some embodiments, the receptacle may be configured to receive various types of snap-fit fasteners, such as cantilever snap-fits, annular snap-fits, torsional snap-fits, tab-and-slot snap-fits, and / or multi-beam snap-fits. When a cantilevered snap-fit is used, the receptacle may include an outermost cross-sectional area that allows for insertion of the cantilever beam. Once inserted, the beam may rest within the receptacle and be retained by an engagement surface or shoulder. In some embodiments, the receptacle geometry may be tailored for annular or torsional snap-fits, for which rotational or radial deflection may provide the locking mechanism.

[0081] In some embodiments, the receptacle may be configured to receive a deformable pin and / or tube. The pin or tube may be inserted into the receptacle with sufficient axial force to cause the head or other insertable portion of the pin or tube to plastically deform under an overhang region within the receptacle. The deformable pin or tube may be composed of a material that is more ductile or plastically deformable than the surrounding part material.

[0082] In some embodiments, the portion of the deformable pin or tube in the receptacle may be expanded via a flaring tool or a mandrel. The expansion may be accomplished by mechanically deforming the pin or tube.

[0083] In some embodiments, the deformable tube may be fluidically connected to at least one void, channel, manifold, and / or other internal chamber within the part. In some embodiments, at least two of these deformable tube connections may be fluidically connected through the internal volume of the part.

[0084] In some embodiments, the exposed portion of the deformable tube may be capped with a barb fitting, a threaded fitting, and / or any other suitable fitting to interface with external plumbing. In some embodiments, multiple fittings may be capped on the same fastener.

[0085] In some embodiments, the receptacle and / or fastener may be heated during installation of the fastener to soften the material, facilitate deformation, and / or relieve stress concentrations. In some embodiments, the fastener may be installed using sufficient mechanical force (e.g., axial pressing or snap engagement) to overcome material resistance and engage the receptacle.

[0086] In some embodiments, the fastener may be cooled before installation to thermally shrink the fastener to aid in installation.

[0087] In some embodiments, the fastener may be configured to seal against the receptacle. The seal may include a gasket, o-ring, soft metal ring or insert, and / or any other suitable other feature that forms a seal between the receptacle and fastener when compressed. The seal may be a radial or face seal. In some embodiments, at least one of the receptacle, fastener, and / or metal insert may be configured to have a greater stiffness than other components of the part, and form a crushed metal seal when the fastener is secured.

[0088] In some embodiments, the seal may be compressed by tapering the receptacle such that the gasket is compressed as the fastener is rotated or otherwise locked into place.

[0089] In some embodiments, the fastener may be configured to seal into the receptacle via a welding process. For example, laser welding may be used around the exposed base of the fastener to bond the fastener to the receptacle.

[0090] In some embodiments, the receptacle may include anti-rotation features to prevent rotational movement of a fastener once installed. The anti-rotation features may include set screws, spring-pins, dowels, keys, and / or other suitable features. The receptacle may include a non-circular geometry, such as a geometry that is keyed, slotted, polygonal (e.g., hexagonal, square, etc.), and / or splined. In some embodiments, the fastener may include a corresponding external profile such that, when inserted, the fastener is rotationally constrained by the engagement between the fastener and the receptacle. For example, a fastener with an elliptical base may be inserted through an elliptical hole and rotated in a circular receptacle to be locked into place.

[0091] In some embodiments, the receptacle may be configured to receive components that support the interfacing of fasteners, such as reinforcing rings, reinforcing sleeves, and / or captive nuts. The receptacle may receive the components prior to interfacing with the corresponding fastener. In some embodiments, the receptacle may support auxiliary hardware such as electrical standoffs, mounting studs, or thermally conductive pads (e.g., by integrating with a platform for the hardware).

[0092] In some embodiments, the metal part may include at least one distributed array of receptacles and / or fasteners across at least one surface. The receptacles may be arranged in a regular and / or irregular spatial pattern, such as a parallel array, a radial pattern, a hexagonal close-packed array, and / or any other suitable pattern. The metal part may include multiple arrays, each array configured to interface with a selected type of component. For example, the part may include an array of receptacles and a corresponding array of fasteners configured to interface with the receptacles. Any subset of the arrays may be selectively interfaced with during or after manufacturing.

[0093] FIG. 3 is a top-down view of a metal part 301. The metal part 301 includes a receptacle 302. The shaded circle represents an externally visible hole intended to receive a fastener. The receptacle 302 may include an undercut 303, which may be hidden beyond the visible hole. The shaded rectangle represents the extent of the undercut 303 within the metal part 301. As shown, the cross-sectional area of the undercut 303 may be generally rectangular, allowing accommodation of a fastener with a non-circular base or engagement profile, such as a rectangular or barbed anchor.

[0094] FIG. 4A depicts a cross-section of a blind rivet 401 inserted into metal parts 402 and 403. As shown, each of the parts 402 and 403 may be formed from at least one metal layer. The parts 402 and 403 may, after being stacked, form a large receptacle 404 for receiving the rivet 401. The receptacle 404 may be formed from voids in the metal layers.

[0095] As shown, the rivet 401 may include a pin 405, a collar 406, and a mandrel 407. The pin 405 and collar 406 may be externally visible, with the mandrel 407 inserted within the receptacle 404. The dimensions of the receptacle 404 may be configured to match at least one feature of the rivet 401. For example, as shown, the minimum diameter of the receptacle 404 may be at least the diameter of the mandrel 407.

[0096] FIG. 4B depicts a cross-section of the rivet 401 after the rivet 401 has been installed. Installing the rivet 401 may include removing the pin 405 and deforming the mandrel 407 under an overhang region within the receptacle 404. This may cause the mandrel 407 to flare out and fasten the parts 402 and 403 together with the collar 406. The rivet 401 may be sealed against the receptacle 404 between the parts 402 and 403 (e.g., using a radial or face seal).

[0097] FIG. 5 depicts a cross-section of a metal part 501. The metal part 501 may be formed from multiple stacked layers (e.g., multiple metal sheets). As shown by the shaded regions, the metal part 501 may include a female component 502 (e.g., a receptacle) and a male component 503 (e.g., a fastener) that are configured to interface with each other. After assembly, the metal part 501 may undergo a forming process to cause the female component 502 and the male component 503 to engage and form a mechanical interlock. For example, the metal part 501 may be mechanically bent to bring the female component 502 and the male component 503 together.

[0098] FIG. 6A depicts a cross-section of a metal part 601 with a plumbed fastener 602 inserted. As shown, the part 601 may be formed from multiple metal layers. The part 601 may include a receptacle 603 with a receptacle hole 604. The receptacle hole 604 may have an elliptical cross-sectional area with the semi-minor axis depicted, and the receptacle 603 may have a circular cross-section with a radius that exceeds the semi-major axis of the elliptical cross-section. The fastener 602 may include multiple functional pieces, such as a barbed fitting 605 for the flow of a fluid into the part and a base 606 for fastening into the receptacle 603. The fastener base 606 may have an elliptical cross-section with semi-major and semi-minor axes less than that of the receptacle hole 604. FIG. 6A depicts the semi-minor axis of the receptacle hole 604 and the semi-minor axis of the fastener base 606 after the fastener 602 is inserted and prior to installation. The fastener base 606 may have a grove cut for a gasket 607 that may be compressed when the fastener 602 is installed.

[0099] FIG. 6B depicts an orthogonal view of the metal part 601 with the plumbed fastener 602 inserted as in FIG. 6A. FIG. 6B depicts the semi-major axis of the receptacle hole 604 and the semi-major axis of the fastener base 606 after the fastener 602 is inserted and prior to installation.

[0100] FIG. 6C depicts a cross-section of the metal part 601 with the plumbed fastener 602 inserted and installed by rotating the fastener base 606. The fastener base 606 may be rotated 90 degrees or any other suitable orientation to install the plumbed fastener 602. FIG. 6C depicts the semi-major axis of the fastener base 606 and the semi-minor axis of the receptacle hole 604 after installation of the fastener 602.

[0101] FIG. 6D depicts an orthogonal view of the metal part 601 with the plumbed fastener 602 inserted and installed as in FIG. 6C. FIG. 6D depicts the semi-minor axis of the fastener base 606 and the semi-major axis of the receptacle hole 604.

[0102] FIG. 7 depicts a metal part 701 with a fluid fitting 702 inserted into the part 701. The fitting 702 may act as a plumbed fastener. The fitting 702 may include an elliptical base 703. The elliptical base 80 may fit into an elliptical opening 704 in the metal part in at least one orientation. After the fitting 702 is inserted, the fitting 702 may be rotated to a position where the fitting 702 may be positively retained. A pre-load may be applied to a gasket or o-ring under the fitting onto the sealing face on the part 701. While FIG. 7 depicts the base 703 and opening 704 as having elliptical shapes, it is to be appreciated that the base 803 and / or opening 704 may have any suitable geometry that can be easily inserted and retained after rotation or translation. Some examples include, but are not limited to, multi-lobed cycloids and polygons.EQUIVALENTS

[0103] The methods, systems, and devices discussed above are examples. Various configurations may omit, substitute, or add various procedures or components as appropriate. For instance, in alternative configurations, the methods may be performed in an order different from that described, and that various steps may be added, omitted, or combined. Also, features described with respect to certain configurations may be combined in various other configurations. Different aspects and elements of the configurations may be combined in a similar manner. Also, technology evolves and, thus, many of the elements are examples and do not limit the scope of the disclosure or claims.

[0104] Embodiments of the present disclosure, for example, are described above with reference to block diagrams and / or operational illustrations of methods, systems, and computer program products according to embodiments of the present disclosure. The functions / acts noted in the blocks may occur out of the order as shown in any flowchart. For example, two blocks shown in succession may in fact be executed substantially concurrent or the blocks may sometimes be executed in the reverse order, depending upon the functionality / acts involved.

[0105] Additionally, or alternatively, not all of the blocks shown in any flowchart need to be performed and / or executed. For example, if a given flowchart has five blocks containing functions / acts, it may be the case that only three of the five blocks are performed and / or executed. In this example, any of the three of the five blocks may be performed and / or executed.

[0106] A statement that a value exceeds (or is more than) a first threshold value is equivalent to a statement that the value meets or exceeds a second threshold value that is slightly greater than the first threshold value, e.g., the second threshold value being one value higher than the first threshold value in the resolution of a relevant system. A statement that a value is less than (or is within) a first threshold value is equivalent to a statement that the value is less than or equal to a second threshold value that is slightly lower than the first threshold value, e.g., the second threshold value being one value lower than the first threshold value in the resolution of the relevant system.

[0107] Specific details are given in the description to provide a thorough understanding of example configurations (including implementations). However, configurations may be practiced without these specific details. This description provides example configurations only, and does not limit the scope, applicability, or configurations of the claims. Rather, the preceding description of the configurations will provide those skilled in the art with an enabling description for implementing described techniques. Various changes may be made in the function and arrangement of elements without departing from the spirit or scope of the disclosure.

[0108] Having described several example configurations, various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the disclosure. For example, the above elements may be components of a larger system, wherein other rules may take precedence over or otherwise modify the application of various implementations or techniques of the present disclosure. Also, a number of steps may be undertaken before, during, or after the above elements are considered.

Claims

1. A metal part formed via an additive manufacturing process, the metal part comprising at least one of a receptacle or a fastener on at least one surface of the metal part.

2. The metal part of claim 1 wherein the receptacle or fastener is configured to be secured with access to the surface of the metal part without needing access to an opposite surface of the metal part.

3. The metal part of claim 1 wherein the additive manufacturing process comprises a laminated object manufacturing process.

4. The metal part of claim 1 wherein the receptacle or fastener is configured to interface with a different surface of the metal part.

5. The metal part of claim 1 wherein the metal part comprises a receptacle and a fastener configured to interface with each other.

6. The metal part of claim 1 wherein the metal part is formed from a plurality of patterned metal sheets.

7. The metal part of claim 1 wherein at least one dimension of the receptacle or fastener is determined based on at least one dimension of a corresponding receptacle or fastener.

8. The metal part of claim 1 wherein the receptacle or fastener is configured to interface with an anchor for mounting a fastener.

9. The metal part of claim 1 wherein the receptacle or fastener comprises a plumbed fastener for receiving fluid into the part.

10. The metal part of claim 1 wherein the plumbed fastener is sealed against the part using at least one of a gasket, o-ring, or software metal ring.

11. A metal part formed via an additive manufacturing process, the process comprising:stacking a plurality of patterned metal sheets; andbonding the patterned metal sheets for forming the metal part, the metal part comprising at least one receptacle on at least one surface of the metal part.

12. The metal part of claim 11 wherein the receptacle is configured to be secured with access to the surface of the metal part without needing access to the opposite surface of the metal part.

13. The metal part of claim 11 wherein the receptacle comprises an external hole and a void within the metal part, the external hole having a cross-sectional area distinct from a cross-sectional area of the void.

14. The metal part of claim 11 wherein at least one dimension of the receptacle is determined based on at least one feature of a corresponding fastener.

15. The metal part of claim 14 wherein the dimension comprises a depth that is at least the insertable length of the corresponding fastener.

16. The metal part of claim 11 wherein the receptacle is configured to receive a deformable pin or tube, the pin or tube configured to deform under an overhang region within the receptacle.

17. A method for forming a metal part via additive manufacturing, the method comprising:stacking a plurality of patterned metal sheets; andbonding the patterned metal sheets for forming the metal part, the metal part comprising at least one of a receptacle or a fastener on at least one surface of the metal part.

18. The method of claim 17 wherein the receptacle or fastener is configured to be secured with access to the surface of the metal part without needing access to an opposite surface of the metal part.

19. The method of claim 17 wherein the receptacle or fastener is configured to interface with a different surface of the metal part.

20. The method of claim 17 further comprising:joining the metal part with an additional metal part using the receptacle or fastener; andsealing the receptacle or fastener between the metal part and the additional metal part.

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