A unitized light weight three dimensionally printed aircraft structure

Abstract

An aircraft wing structure includes a wing box substructure and spar caps. The wing box substructure may include one or more structures. Each of the structures may include spar webs, rib portions connecting the spar webs, and a plurality of attachment features. At least one of the structures may be a unitary7 structure formed by additive manufacturing. The spar caps may be fixed to the plurality of attachment features and configured to connect the structures together. The spar caps may include unidirectional carbon fibers. The aircraft wing structure may further include a cover, such that the unidirectional carbon fibers may be within the cover. The cover may be configured to prevent the unidirectional carbon fibers from buckling under axial compression. The aircraft wing structure may further include a fixing feature coupling a portion of a first structure to a portion of a second structure.

Description

Ref. No. <038191.01372>A UNITIZED LIGHT WEIGHT THREE DIMENSIONALLY PRINTED AIRCRAFT STRUCTURECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No.63 / 760,081, entitled “Unitized Light Weight 3-D Printed Aircraft Wing Structure” and filed on February 18, 2025. U.S. Provisional Application Serial No. 63 / 866,962, entitled “Pod-Modular Logistics Aircraft” and filed on August 19, 2025 and U.S. Provisional Application Serial No. 63 / 877,938, entitled “Unitized Light Weight 3-D Printed Aircraft Wing Structure” and filed on September 8, 2025, which are expressly incorporated by reference herein in their entirety.BACKGROUNDField

[0002] The disclosure relates generally to a structure and methods of manufacturing and assembling structures for an aircraft.Background

[0003] Three-dimensional (3D) printing, also referred to as additive manufacturing (AM), has recently presented new opportunities to more efficiently build complex transport structures (e.g., manned or autonomous transport structures) and joined / assembled structures that form or form portions of automobiles, aircraft, drones, boats, motorcycles, buses, trains, and the like. AM techniques are capable of fabricating complex structures from various materials. Applying AM processes to industries that produce these structures has proven to produce a structurally more efficient transport structure. For example, an aircraft or portions of an aircraft produced using one or more 3D printed structures may be made stronger, lighter, and consequently, more fuel efficient. Moreover, AM enables manufacturers to 3D print structures that are more complex in shape and form and that are equipped with more advanced features and capabilities than structures made using traditional machining and casting techniques.Ref. No. <038191.01372>SUMMARY

[0004] Several aspects of a structure and methods of joining / assembling of structures will be described more fully hereinafter. Also, three-dimensional printing techniques of these structures will be described.

[0005] In one or more embodiments disclosed herein is an aircraft wing structure including four composite spar caps and a wing box substructure. The wing box substructure may include one or more structures. Each of the structures may include two spar webs, rib portions connecting the two spar webs, and a plurality of attachment features. The four composite spar caps may be fixed to the plurality of attachment features.

[0006] In one or more embodiments, an adhesive may fix the composite spar caps to the attachment features.

[0007] In one or more embodiments, each of the plurality of attachment features may include an opening. Each of the openings may be configured to contain one of the four composite spar caps.

[0008] In one or more embodiments, the four composite spar caps may include carbon fibers combined with a resin.

[0009] In one or more embodiments, the four composite spar caps may include carbon fibers.

[0010] In one or more embodiments, the carbon fibers may include unidirectional carbon fibers.

[0011] In one or more embodiments, the aircraft wing structure may include a cover, such that the unidirectional carbon fibers may be within the cover. The cover may be configured to prevent the carbon fibers from buckling under axial compression.

[0012] In one or more embodiments, the cover may include a plurality of apertures.

[0013] In one or more embodiments, the cover may include a coating configured to prevent galvanic corrosion between the cover and the carbon fibers.

[0014] In one or more embodiments, the cover may include a metal. For example, the metal may be an alloy, for example, an aluminum alloy.

[0015] In one or more embodiments, the wing box substructure may include a plurality of the structures. The four composite spar caps may connect the plurality of structures together.Ref. No. <038191.01372>

[0016] In one or more embodiments, the aircraft wing structure may include a propulsor coupled to the wing box substructure.

[0017] In one or more embodiments, two of the attachment features of one of the structures may be fixed to one of the spar caps, and the two attachment features may be separated by a gap.

[0018] In one or more embodiments, one of the attachment features of a first structure of the plurality of structures may span one of the two spar webs of the first structure.

[0019] In one or more embodiments, at least one of the structures may be a unitary structure.

[0020] In one or more embodiments, the unitary structure may be a three dimensionally printed metal structure. For example, the three dimensionally printed metal structure may be powder bed fusion printed or printed using other additive manufacturing (AM) methods / techniques. Also, the unitary metal structure may be. for example, an alloy structure, for example, an aluminum alloy structure.

[0021] In one or more embodiments, the plurality of structures may span the aircraft wing structure.

[0022] In one or more embodiments, the aircraft wing structure may include a skin coupled to the rib portions of one or more of the plurality of structures.

[0023] In one or more embodiments, the aircraft wing structure may include a fixing feature coupling a first portion of a first structure of the plurality of structures to a second portion of a second structure of the plurality of structures.

[0024] In one or more embodiments, the fixing feature may include a protrusion coupled to the first portion, and a recess coupled to the second portion. The protrusion may be connected to the recess with an adhesive.

[0025] In one or more embodiments, an aircraft architecture may comprise a core system; and a plurality' of substitutable systems configured to be interchangeably coupled to the core system, the plurality of substitutable systems comprises a container system and a propulsion system, and wherein the container system is configured to transfer energy and electrical signals to the propulsion system.

[0026] In one or more embodiments, the plurality of substitutable systems may further comprise a tail system configured to be coupled to the core system.Ref. No. <038191.01372>

[0027] In one or more embodiments, the container system may comprise a power source generating energy, such that the generated energy is supplied to the propulsion system.

[0028] In one or more embodiments, the propulsion system may comprise one or more propulsors.

[0029] In one or more embodiments, the container system may comprise a plurality of containers configured to be coupled together.

[0030] In one or more embodiments, the plurality of substitutable systems may further comprise a wing system configured to be coupled to the core system.

[0031] In one or more embodiments, the propulsion system may be coupled to the wing system.

[0032] In one or more embodiments, the core system may comprise a plurality of structures, wherein the plurality of structural comprises a plurality of unitary structures coupled together, and wherein the wing system is connected to and removeable from one or more of the unitary structures.

[0033] In one or more embodiments, the wing system may comprise two wings, wherein a first wing is connected to and removeable from a first unitary structure of the plurality7of unitary structures and a second wing is connected to and removeable from a second unitary structure of the plurality of unitary structures.

[0034] In one or more embodiments, the aircraft architecture may further comprise a plurality of composite booms, and wherein the plurality of structures are coupled together with the plurality7of composite booms.

[0035] It will be understood that other aspects of the structures and methods of joining / assembling of the structures will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described several embodiments only by way of illustration. As will be realized by those skilled in the art, the structures and methods of joining / assembling of the structures are capable of other and different embodiments, and its several details are capable of modification in various other respects, all without departing from the disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.Ref. No. <038191.01372>BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Various aspects of a structure and methods of joining / assembling structures will now be presented in the detailed description by way of example, and not by way of limitation, in the accompanying drawings, wherein:

[0037] FIGS. 1A-1D illustrate respective side views of a 3-D printer system in accordance with an aspect of the present disclosure.

[0038] FIG. IE illustrates a functional block diagram of a 3-D printer system in accordance with an aspect of the present disclosure.

[0039] FIG. 2 illustrates a perspective view of an example wing box substructure in accordance with an aspect of the present disclosure.

[0040] FIG. 3 illustrates a perspective view of an example wing box substructure in accordance with an aspect of the present disclosure.

[0041] FIG. 4 illustrates a perspective view of an example wing box substructure in accordance with an aspect of the present disclosure.

[0042] FIG. 5 illustrates a perspective view of an example wing box substructure in accordance with an aspect of the present disclosure.

[0043] FIG. 6 illustrates a perspective view of an example wing box substructure in accordance with an aspect of the present disclosure.

[0044] FIG. 7 illustrates a perspective view of an example wing box substructure in accordance with an aspect of the present disclosure.

[0045] FIG. 8 illustrates a perspective view of an example wing box substructure with spar caps fixed thereto.

[0046] FIG. 9 illustrates a perspective view of example wing box substructures fixed to and connected together with spar caps.

[0047] FIG. 10 illustrates a perspective view of an example aircraft wing formed of a plurality of structures connected together with a plurality of spar caps.

[0048] FIG. 11 illustrates front, side and perspective views of a structure including a mount for an engine.

[0049] FIG. 12 illustrates a perspective view of an example structure including an attachment feature containing a spar cap, where the spar cap is within a cover.

[0050] FIG. 13 illustrates a perspective exploded view of an example cover configured to be secured / clamped to a spar cap.Ref. No. <038191.01372>

[0051] FIG. 14 illustrates a perspective view of an example cover secured / clamped to a spar cap.

[0052] FIG. 15 illustrates details of a fastener end clamp securing a cover to a spar cap.

[0053] FIG. 16 illustrates details of an apparatus end clamp securing a cover to a spar cap.

[0054] FIG. 17 illustrates a perspective exploded view of an aircraft wing structure including the structures / wing box substructure configured to be connected with the spar caps.

[0055] FIG. 18 illustrates a perspective view of the aircraft wing structure including the structures / wing box substructure connected with the spar caps.

[0056] FIG. 19 illustrates a perspective view of the aircraft wing structure including a skin, and the structures / wing box substructure connected with the spar caps being / positioned within the skin.

[0057] FIG. 20 illustrates a perspective view of the skin of the aircraft wing structure enclosing the structures / wing box substructure, which are / is connected by the spar caps.

[0058] FIG. 21 illustrates a perspective view of an aircraft, where the aircraft has an architecture such that its systems (e.g., structural systems such as its wing(s), fuselage, nose, tail, landing gear, etc.) are interchangeable (i.e., substitutable / swapable / modular).

[0059] FIG. 22 illustrates a perspective view of two containers of a container system coupled together and coupled to the aircraft, and the aircraft’s engines mounted below the wing.

[0060] FIG. 23 illustrates a perspective exploded view of the skins separated from the aircrafts' interchangeable core system, and the two containers configured to be coupled together and coupled to the aircraft such as the aircraft’s interchangeable core system.

[0061] FIG. 24 illustrates a perspective view of the two containers coupled together and coupled to the aircraft, where the aircraft have different engine types and the engines are mounted above and below the wing.

[0062] FIG. 25 illustrates a detailed perspective view of the aircrafts' interchangeable core sy stem and landing gear.Ref. No. <038191.01372>

[0063] FIG. 26 illustrates a detailed exploded perspective view of the landing gear separated from the aircrafts' interchangeable core system.

[0064] FIG. 27 illustrate perspective views of details and assembly of a structure of the front structure.

[0065] FIG. 28 illustrates a detailed view of the structure of the front structure.

[0066] FIG. 29 illustrate perspective views of details and assembly of structures of the front structure.

[0067] FIG. 30 illustrate perspective views of assembled and connected structures of the front structure assembled.

[0068] FIG. 31 illustrates a detailed side view of the structure of the front structure.

[0069] FIG. 32 illustrate perspective views of front and aft structures being connected to core booms.

[0070] FIG. 33 illustrate perspective views of the front structure, the aft structure and an intermediate structure being connected to core booms.

[0071] FIG. 34 illustrate perspective views of the front structure, the aft structure, the intermediate structure and a frame structure being connected to core booms.

[0072] FIG. 35 illustrate perspective views connecting a front tip structure to the front structure, and connecting a rear tip structure to the aft structure.

[0073] FIG. 36 illustrates landing gear coupled to the front and aft structures.

[0074] FIG. 37 illustrates an example wing of the wing system.

[0075] FIG. 38 illustrates the wings of the wing system configured to connect to the front structure.

[0076] FIG. 39 illustrates an exploded view of the skins to be attached to the aircraft and a view of the skin attached to the aircraft.

[0077] FIG. 40 illustrates perspective views of the two containers configured to be coupled together and coupled together and coupled to the aircraft.DETAILED DESCRIPTION

[0078] The detailed description set forth below in connection with the drawings is intended to provide a description of example embodiments of a structure and methods of manufacturing and assembling structures for an aircraft. For example, the structuresRef. No. <038191.01372>

[0079] and the joined / assembled structures that form or form portions of automobiles, aircraft, drones, boats, motorcycles, buses, trains, and the like may include AM structures or other manufactured structures. The structures, systems and methods are not intended to represent the only embodiments in which the disclosure may be practiced. The terms “exemplary'’ or "example" used throughout this disclosure means “serving as an example, instance, or illustration.” and should not necessarily be construed as preferred or advantageous over other embodiments presented in this disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that fully conveys the scope of the disclosure to those skilled in the art. However, the disclosure may be practiced without these specific details. In some instances, well-known structures and components may be shown in block diagram form, or omitted entirely, in order to avoid obscuring the various concepts presented throughout this disclosure.

[0080] 3D printing one or more aircraft structures, such as aircraft wings and fuselages, may have a number of advantages. For example, 3D printed structures may be topologically optimized to reduce weight while maintaining or exceeding performance requirements. 3D printing may help reduce part count, reduce the number of manufacturing and assembly operations to form the aircraft structure and reduce costs by eliminating the need for jigs, presses, molds and machining of the structures. Also, 3D printing a structure for an aircraft structure may allow the structure to have a high strength to weight ratio, which may reduce the weight of the structure and thus, of the aircraft structure. Additionally, 3D printing the structure may allow for an optimized shape / geometry (e.g., a complex shape / geometry) of the structure such that the structure may fit within a desired small area or volume and may provide superior energy and stress distribution / absorption. The 3D printed structure may be formed using layers of material based on a digital model data of the structure. A 3D printer may form the structure defined by the digital model data by printing the structure one layer at a time or by other AM techniques.

[0081] 3D printing provides geometric and design flexibility that conventional manufacturing processes may not be able to obtain. For example, 3D printing technologies can produce structures with very small feature sizes, and geometriesRef. No. <038191.01372>that are either significantly difficult or impossible to produce using conventional manufacturing processes.

[0082] However, despite the potential advantages of 3D printing structures, one disadvantage to 3D printing is the limited size of each individual 3D printed structure. For example, modem LPBF printers are limited in the volume of structure printed, e.g., less than 1 cubic meter of material printed at once. Aircraft structures such as a wing and a fuselage, whose lengths are greater than the current volumetric limitations of 3D printers, could at best be printed in sections as the printer allows. This presents a significant problem in how to take advantage of the material optimization provided by 3D printing while overcoming its shortcomings at creating large, contiguous structures.

[0083] The present disclosure provides a solution. The disclosure includes for example, an aircraft structure (e.g., wing or fuselage) having spar caps fixed to one or more 3D printed structures and connecting together the structures, where the spar caps are sized to take / support tension or compression loads resulting from the bending moments on the aircraft structure (e.g., wing or fuselage). The spar caps may include carbon fibers. The carbon fibers may or may not be combined within a resin, such as an epoxy. The carbon fibers may be unidirectional carbon fibers. The unidirectional carbon fibers may be combined with a resin or may not be combined with a resin, but rather are bundled together. The carbon fibers may be within a cover. One or more of the structures may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure. The unitary7structure may be formed by 3D printing such as laser bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E.

[0084] Additive Manufacturing

[0085] Additive Manufacturing (AM) involves the use of a stored geometrical model for accumulating layered materials on a build plate to produce a three- dimensional (3D) build piece having features defined by the model. AM techniques are capable of printing simple and complex structures using a wide variety of materials. A 3D structure may be fabricated based on a computer aided design (CAD) model. The CAD model can be used to generate a set ofRef. No. <038191.01372>instructions or commands that are compatible with a particular 3D printer. The AM process can create / manufacture a three-dimensional structure using the CAD model and print instructions. In the AM process, different materials or combinations of material, such as engineered plastics, thermoplastic elastomers, metals, ceramics, and / or alloys or combinations of the above, etc., may be used to create a three-dimensional structure.

[0086] The use of producing AM structures may provide significant flexibility and cost saving benefits. These, and other benefits may enable manufacturers of mechanical structures to produce the structures at a lower cost and in a more efficient manner. The techniques described in the present disclosure relate to a structure and methods of manufacturing and assembling structures for an aircraft, where the structures may be AM structures, and / or other manufactured structures, and / or commercial off the shelf (COTS) structures. AM structures are 3D structures that are printed by, for example, adding layer upon layer of one or more materials based on a preprogramed design. For example, the structure may be formed by a powder bed fusion (PBF) system / prmter. The structures described herein may be structures used to assemble a variety of devices and apparatuses, such as a wing, a fuselage or other aircraft structures as well as other structural components and structures such as bridges, etc. Further, such AM and / or COTS structures may be used in assemblies, such as automobiles, aircraft, drones, boats, motorcycles, buses, trains, and the like, or other mechanized assemblies, without departing from the scope of the present disclosure. Assembly of these structures may be performed robotically (e.g., by robots) or manually or a combination of manual and robotic assembly.

[0087] Structures and Terminology in AM

[0088] In an aspect of the present disclosure, a structure may be an example of an AM structure or a structure manufactured by other manufacturing methods. The structure may include structures joined together that form part of or form automobiles, aircraft, drones, boats, motorcycles, buses, trains, and their components, and the like. A structure may be any 3D printed structure that includes features, such as an interface, for mating with another component. The structure may have internal or external features configured to accept a particular type of structure. Alternatively or additionally, the structure may be shaped toRef. No. <038191.01372>accept a particular pe of structure. A structure may utilize any internal design or shape and accept any variety of structures without departing from the scope of the disclosure.

[0089] A structure interface may be configured to connect to an interface of another structure. For example, and not by way of limitation, an interface between structures may include a tongue-and-groove structure. The interface may include high precision features or complex geometries that allow them to perform specific functions, including creating connections to spanning structures such as tubes, structural panels, extrusions, sheet metal, and / or other structural members.

[0090] For clarity, structures may also include relatively simple connection features configured to connect with a more sophisticated network of connection features of the interface to form streamlined connections between structures. While these structures may incorporate more basic features, they advantageously may be 3D printed at a higher print rate. Alternatively, structures may be built / manufactured using any 3D print manufacturing or other manufacturing technology’.

[0091] A number of different AM technologies may be well-suited for construction of structures in a transport structure or other mechanized assembly. Such 3D printing techniques may include, for example, directed energy' deposition (DED), selective laser melting (SLM), selective laser sintering (SLS), direct metal laser sintering (DMLS), electron beam melting (EBM), powder bed fusion (PBF), and / or other AM processes involving melting or fusion of metallic powders.

[0092] As in many 3D printing techniques, these systems and processes (e.g., PBF systems and processes) can create build pieces (e.g., structures) layer-by-layer. Each layer or “slice” is formed by depositing a layer of powder and exposing portions of the powder to an energy' beam. The energy beam is applied to melt areas of the pow der layer that coincide w ith the cross-section of the build piece in the layer. The melted powder cools and fuses to form a slice of the build piece. The process can be repeated to form the next slice of the build piece, and so on. Each layer is deposited on top of the previous layer. The resulting structure is a build piece assembled slice-by-slice from the ground up. SLS and various other PBF techniques may be well suited to construction of structures for aircraft and other transport structures and components. However, it will be appreciated thatRef. No. <038191.01372>other AM techniques, such as fused deposition modeling (FDM) and the like, are also possible for use in such applications.

[0093] While the disclosure relates to AM structures of aircraft wings and fuselages, the techniques described in his disclosure are not only applicable to AM structures or aircraft structures. For instance, the techniques may be applied to structures of other transport structures or bridges. In addition, while the disclosure also describes AM structures, any suitable technique for manufacturing structures may be used without departing from the scope of the disclosure.

[0094] AM may include the manufacture of one or more structures. Using AM, a structure may be constructed to include additional features and functions, including interface functions, depending on the objectives.

[0095] As a consequence of the capabilities of AM discussed above, the present disclosure is directed to designing, creating and manufacturing structures such as aircraft wings and fuselages, which are lightweight, strong, and cost efficient and consequently, these structures produce a fuel efficient transport vehicle, such as an aircraft. In one or more embodiments, the disclosure describes an aircraft wing and / or fuselage that may be formed of a plurality of un itary structures connected together by light weight composite spar caps. The structures may be formed from AM techniques / processes and this enables a truly optimized strong, lightweight and shaped structure as well as enables time and cost efficient robotic assembly of forming the wing and / or fuselage by connecting these structures together with light weight and strong spar caps.

[0096] Additive Manufacturing Environment

[0097] FIGS. 1 A-1D illustrate respective side views of a 3D printer system (e.g., a PBF system) in an aspect of the present disclosure.

[0098] In an aspect of the present disclosure, a 3D printer system may be a powder-bed fusion (PBF) system 100. FIGS. 1A-D show PBF system 100 during different stages of operation. The particular embodiment illustrated in FIGS. 1 A-1D is one of many suitable examples of a PBF system employing principles (e.g. creating and manufacturing one or more structures) of this disclosure. It should also be noted that elements of FIGS. 1A-1D and the other figures in this disclosure are not necessarily drawn to scale, but may be drawn larger or smaller for the purpose of better illustration of concepts described herein. PBF system 100 may includeRef. No. <038191.01372>a depositor 101 that can deposit each layer 125 of powder 117 (e.g., metal powder), an energy beam source 103 that can generate an energy beam 127, a deflector 105 that can apply the energy beam to fuse the powder material, and a build plate 107 that can support one or more build pieces, such as a build piece 109. Although the terms “fuse” and / or “fusing” are used to describe the mechanical coupling of the powder particles, other mechanical actions, e.g., sintering, melting, and / or other electrical, mechanical, electromechanical, electrochemical, and / or chemical coupling methods are envisioned as being within the scope of the present disclosure.

[0099] PBF system 100 may also include a build floor 111 positioned within a powder bed receptacle. The walls 112 of the powder bed receptacle generally define the boundaries of the powder bed receptacle, which is sandwiched between the walls 112 from the side and abuts a portion of the build floor 111 below. Build floor 111 can progressively lower build plate 107 so that depositor 101 can deposit a next layer. The entire mechanism may reside in a chamber 113 that can enclose the other components, thereby protecting the equipment, enabling atmospheric and temperature regulation and mitigating contamination risks. Depositor 101 may include a hopper 115 that contains a powder 117, such as a metal powder, and a leveler 119 that can level the top of each layer of deposited powder.

[0100] Referring specifically to FIG. 1A, FIG. 1A illustrates PBF system 100 after a slice of build piece 109 has been fused, but before the next layer of powder has been deposited. In fact, FIG. 1A illustrates a time at which PBF system 100 has already deposited and fused slices in multiple layers, e.g., 200 individual layers, to form the current state of build piece 109, e.g., formed of 200 individual slices. The multiple individual layers already deposited have created apowder bed 121, which includes powder that was deposited but not fused.

[0101] FIG. IB illustrates PBF system 100 at a stage in which build floor 111 can lower by a powder layer thickness 123. The lowering of build floor 111 causes build piece 109 and powder bed 121 to drop by powder layer thickness 123, so that the top of build piece 109 and powder bed 121 are lower than the top of powder bed receptacle wall 112 by an amount equal to the powder layer thickness 123. In this way, for example, a space with a consistent thickness equal to powder layerRef. No. <038191.01372>thickness 123 can be created over the tops of build piece 109 and powder bed 121.

[0102] FIG. 1C illustrates PBF system 100 at a stage in which depositor 101 is positioned to deposit powder 117 in a space created over the top surfaces of build piece 109 and powder bed 121 and bounded by powder bed receptacle walls 112. In this example, depositor 101 progressively moves over the defined space while releasing powder 117 from hopper 115. Leveler 119 can level the released powder to form a powder layer 125 that leaves powder layer top surface 126 configured to receive fusing energy from energy' beam source 103. Powder layer 125 has a thickness substantially equal to the powder layer thickness 123 (see FIG. IB). Thus, the powder in a PBF system can be supported by a powder material support structure, which may include, for example, a build plate 107, a build floor 111, a build piece 109, walls 112, and the like. It should be noted that the illustrated thickness of powder layer 125 (i.e., powder layer thickness 123 (FIG. IB)) is greater than an actual thickness used for the example involving the 200 previously-deposited individual layers discussed above with reference to FIG. 1A.

[0103] FIG. ID illustrates PBF system 100 at a stage in which, following the deposition of powder layer 125 (FIG. 1C), energy beam source 103 generates an energy beam 127 and deflector 105 applies the energy beam to fuse the next slice in build piece 109. In various embodiments, energy beam source 103 may be an electron beam source, in which case energy beam 127 constitutes an electron beam. Deflector 105 may include deflection plates that can generate an electric field or a magnetic field that selectively deflects the electron beam to cause the electron beam to scan across areas designated to be fused. In various embodiments, energy beam source 103 may be a laser, in which case energy beam 127 is a laser beam. Deflector 105 may include an optical system that uses reflection and / or refraction to manipulate the laser beam to scan selected areas to be fused.

[0104] In various embodiments, the deflector 105 may include one or more gimbals and actuators that can rotate and / or translate the energy beam source to position the energy beam. In various embodiments, energy beam source 103 and / or deflector 105 can modulate the energy beam, e g., turn the energy beam on and off as theRef. No. <038191.01372>deflector scans so that the energy beam is applied only in the appropriate areas of the powder layer. For example, in various embodiments, the energy beam may be modulated by a digital signal processor (DSP).

[0105] FIG. IE illustrates a functional block diagram of a 3D printer system in accordance with an aspect of the present disclosure.

[0106] In an aspect of the present disclosure, control devices and / or elements, including computer software, may be coupled to PBF system 100 to control one or more components within PBF system 100. Such a control device may be a computer 150, which may include one or more components that may assist in the control of PBF system 100. Computer 150 may communicate with a PBF system 100, and / or other AM systems, via one or more interfaces 151. The computer 150 and / or interface 151 are examples of devices that may be configured to implement the various methods described herein, that may assist in controlling PBF system 100 and / or other AM systems.

[0107] In an aspect of the present disclosure, computer 150 may include one or more processor units 152, memory 154, a signal detector 156, a digital signal processor (DSP) 158, and one or more user interfaces 160. Computer 150 may include additional components without departing from the scope of the present disclosure.

[0108] The computer 150 may include one or more processor units 152, which may assist in the control and / or operation of PBF system 100. The processor unit 152 may also be referred to as a central processing unit (CPU). Memory 154, which may include both read-only memory (ROM) and random access memory (RAM), may provide instructions and / or data to the processor. A portion of the memory 154 may also include non-volatile random access memory (NVRAM). The processor 152 typically performs logical and arithmetic operations based on program instructions stored within the memory' 154. The instructions in the memory 154 may be executable (by the processor unit 152, for example) to implement the methods described herein.

[0109] The processor unit 152 may comprise or be a component of a processing system implemented with one or more processors. The one or more processors may be implemented with any combination of general-purpose microprocessors, microcontrollers, digital signal processors (DSPs), floating point gate arraysRef. No. <038191.01372>(FPGAs), programmable logic devices (PLDs), controllers, state machines, gated logic, discrete hardware components, dedicated hardware finite state machines, or any other suitable entities that can perform calculations or other manipulations of information.

[0110] The processor unit 152 may also include machine-readable media for storing software. Software shall be construed broadly to mean any type of instructions, whether referred to as software, firmware, middleware, microcode, hardware description language, or otherwise. Instructions may include code (e.g., in source code format, binary code format, executable code format, RS-274 instructions (G-code), numerical control (NC) programming language, and / or any other suitable format of code). The instructions, when executed by the one or more processors, cause the processing system to perform the various functions described herein.

[0111] The computer 150 may also include a signal detector 156 that may be used to detect and quantify any level of signals received by the computer 150 for use by the processing unit 152 and / or other components of the computer 150. The signal detector 156 may detect such signals as energy beam source 103 power, deflector 105 position, build floor 111 height, amount of powder 117 remaining in depositor 101, leveler 119 position, and other signals. Signal detector 156, in addition to or instead of processor unit 152 may also control other components as described with respect to the present disclosure. The computer 150 may also include a DSP 158 for use in processing signals received by the computer 150. The DSP 158 may be configured to generate instructions and / or packets of instructions for transmission to PBF system 100.

[0112] The computer 150 may further comprise a user interface 160 in some aspects.The user interface 160 may include a keypad, a pointing device, and / or a display. The user interface 160 may include any element or component that conveys information to a user of the computer 150 and / or receives input from the user.

[0113] The various components of the computer 150 may be coupled together by a bus system 151. The bus system 151 may include a data bus, for example, as well as a power bus, a control signal bus, and a status signal bus in addition to the data bus. Components of the computer 150 may be coupled together or accept or provide inputs to each other using some other mechanism.Ref. No. <038191.01372>

[0114] Although a number of separate components are illustrated in FIG. IE, one or more of the components may be combined or commonly implemented. For example, the processor unit 152 may be used to implement not only the functionality described above with respect to the processor unit 152, but also to implement the functionality described above with respect to the signal detector 156, the DSP 158, and / or the user interface 160. Further, each of the components illustrated in FIG. IE may be implemented using a plurality of separate elements.

[0115] By w ay of example, an element, or any portion of an element, or any combination of elements may be implemented using one or more processors. Examples of processors include microprocessors, microcontrollers, graphics processing units (GPUs), central processing units (CPUs), application processors, digital signal processors (DSPs), reduced instruction set computing (RISC) processors, systems on a chip (SoC), baseband processors, field programmable gate arrays (FPGAs), programmable logic devices (PEDs), state machines, gated logic, discrete hardware circuits, and other suitable hardware configured to perform the various functionality described throughout this disclosure. One or more processors may execute software as described above.

[0116] In one or more aspects, the functions described may be implemented in hardware, softw are, firmware, or any combination thereof. If implemented in software, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium. Computer-readable media includes both computer storage media and communication media including any medium that facilitates transfer of a computer program from one place to another. A storage media may be any available media that can be accessed by a computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, compact disc (CD) ROM (CD-ROM) or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to cany' or store desired program code in the form of instructions or data structures and that can be accessed by a computer. Disk and disc, as used herein, includes CD, laser disc, optical disc, digital versatile disc (DVD), floppy disk and Blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Thus, computerRef. No. <038191.01372>readable medium includes a non-transitory computer readable medium (e.g., tangible media).

[0117] Apparatus, System and Assembly Process

[0118] Throughout this entire disclosure, a wing includes a fixed wing and a rotary wing.

[0119] The disclosure provides example apparatuses, systems and processes for forming structures such as aircraft wings and fuselages, which are lightweight, strong, and cost efficient. In one or more embodiments, aircraft wings and fuselages may be formed from a plurality of unitary AM structures connected together by composite spar caps. More details of the features and processes of these structures will be described below.

[0120] Because the spar caps are configured to resist bending and support compression and tension loads from an aircraft structure such as a wing and a fuselage and are to be light weight, the spar caps may include a composite including carbon fibers. The carbon fibers may be unidirectional carbon fibers. The unidirectional (UD) carbon fibers may be bundled together and aligned in a direction of a force applied thereto. Spar caps made from carbon fibers compared to metal spar caps such as aluminum may be much lighter and stronger. For example, a carbon fibers' elastic modulus and tensile strength are much larger than those of aluminum, while its density is much lower as shown in below Table 1.Aluminum UD Carbon x ARSCFRP Fibers for comp. E [GPa] 70.4 452 6.4x 60[MPa] 385 4,889 13x 986 p [g / cm3] 2.69 1.83 0.7x 1.48Table 1

[0121] Comparison of Carbon Fiber Spar Caps to Aluminum Spar Caps in Tension

[0122] When unidirectional (UD) carbon fibers form a UD rod, the UD rod is approximately 33 percent lighter than an aluminum rod of the same crosssection. Also, where a carbon fiber rod and an aluminum rod have the sameRef. No. <038191.01372>cross-section, the carbon fiber rod can carry seven times the load of the aluminum rod while only weighing two-thirds of the aluminum rod.

[0123] Comparison of Carbon Fiber Spar Caps to Aluminum Spar Caps in Compression

[0124] Where a carbon fiber rod and an aluminum rod have the same cross-section, the carbon fiber rod can carry three times the load (e.g., Euler buckling) of the aluminum rod while only weighing two-thirds of the aluminum rod.

[0125] From the above comparisons, for the same cross-section, aluminum would be about ten times heavier than carbon fibers to carry the same load under tension, and five times heavier than carbon fibers to carry the same load under compression. A thin cover may be placed around / encase the UD carbon fibers for further strength enhancement and for keeping the UD carbon fibers in a desired alignment.

[0126] Furthermore, because the wing box substructure may have a spar cap coupled / connected (e.g. , coupled to an attachment feature, which may be coupled to the spar web) to an upper portion of a spar web of the structure and another spar cap coupled / connected (e.g., coupled to another attachment feature, which may be coupled to the spar web) to a lower portion of the spar web, the structure may be ideally modeled as a beam, where the spar caps support and react to tension and compression and the spar web supports and carries shear (e.g., shear forces). Thus, the spar caps function as columns in tension and compression. From Table 1, when the spars caps are under tension and made from UD carbon fibers, the UD spar caps have an ultimate tensile strength (cruit) 13x (i. e. , 13 times) greater than aluminum spar caps, where the UD spar caps and the aluminum spar caps have the same geometry. The limiting factor for the compression side would 7T2Elbe Euler’s buckling, whose critical load is given by P =which means that, for the same geometry, the load is dictated by the elastic modulus and thus, for the same geometry, the compressive load is increased about six times and all that with a 30% weight reduction. Therefore, connecting the structures of a wing box together with carbon fiber composite spar caps may superiorly increase the strength and reduce the weight of an aircraft structure or other vehicle structures.

[0127] FIG. 2 illustrates an example wing box substructure 200. As will be later shown and disclosed, a wing may include a wing box substructure. As illustrated in FIG.2, the wing box substructure may include two structures 201 coupled together atRef. No. <038191.01372>a connection 215. Each structure 201 illustrated in FIG. 2 includes two spars webs 202 and 203, a plurality of rib portions (e.g., rib portions 204, 205. 206, 207, and 208) and a plurality of attachment features 209, 210, 211, and 212. The spars webs are configured to support shear forces resulting from loads originated from the aircraft structure. The rib portions may be configured to be attach to a skin of a wing. The rib portions may provide the aerodynamic profile of the wing, provide structural support for the wing skin(s) and provide support for compressive loads. The skin(s) may support torsional loads from the wing. One or more of the rib portions may connect between any two attachment features and are connecting the two spar webs of the structure (i.e., connect the two spar webs 202 and 203 via coupled to the attachment features). Each of the attachment features may include an opening 213 configured to receive a spar cap (see FIGS.8-10). In one or more embodiments, the two coupled / connected structures may include four spar caps, where each spar cap is inserted within and fixed to a corresponding attachment feature. For example, the spar cap may be fixed to the attachment feature via an adhesive, a screw, a nut and bolt, a rivet or other fastening device(s), where the spar caps may include carbon fibers combined with a resin or include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together and the attachment features may include metal such as an alloy or aluminum alloy. The carbon fibers or the dry carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. In one or more embodiments, each structure may include spar caps inserted within and fixed to a corresponding attachment feature and thus, the two coupled / connected structures may include four spar caps and eight attachment features. In one or more embodiments, the attachment features may function as a spar cap and include a composite including carbon fibers combined with a resin or include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together. In such an embodiment, the attachment features functioning as a spar cap will not require spar caps inserted therein. The carbon fibers or the dry carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. Each of the spar webs may include one or more apertures 214, such as six apertures as illustrated in FIG. 2. The apertures may reduce theRef. No. <038191.01372>weight of the structure and provide routing of fluid and electrical lines and / or other systems for which need to be routed through / throughout the wing box substructure. Additionally or alternative, the apertures may be configured to receive and mount a propulsion device such as a propulsor. In one or more embodiments, the propulsion device may include an engine. The connection 215 may be a connection between the surfaces of the spar webs or one or more joints between the structures. In one or more embodiments, the connection may include a fixing feature coupling a portion (e.g., a first portion) of a structure (e.g., a first structure) to a portion (e.g., a second portion) of another structure (e.g., a second structure). The fixing feature may include a protrusion coupled to the portion of, for example, the first structure and a recess coupled to the portion of, for example, the second structure. An adhesive may be provided within the recess and / or on the protrusion such that the adhesive connects the protrusion to the recess, and consequently further (i.e., along with the spar caps) connect the structures together. In one or more embodiments, the protrusion may be coupled to one or more of the spar caps and / or spar webs and the recess may be coupled to one or more of the spar caps and / or spar webs. The number and / or shape and / or size of the structures, rib portions, spar caps, spar webs, openings and apertures may be different from the number, shape and size illustrated in FIG. 2. For example, the number of rib portions and attachment features of a first structure and the shape of the openings and the first structure may be different from the number of rib portions and the attachment features of a second structure and the shape of the openings and the second structure. One or more of the structures may include a metal or an alloy, for example, an aluminum alloy structure. One or more of the structures may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure. The unitary structure may be formed by 3D printing such as laser powder bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E.

[0128] FIG. 3 illustrates an example wing box substructure 300. As illustrated in FIG.3, the wing box substructure may include four structures 301 coupled together at connections 309, 310, and 311. Each structure 301 illustrated in FIG. 3 includesRef. No. <038191.01372>two spars webs 302 and 303, a plurality of rib portions 304 and a plurality (four illustrated in FIG. 3) of attachment features (e.g.. 305 and 306). The spars webs are configured to support shear forces resulting from loads originated from the aircraft structure. The rib portions may be configured to be attach to a skin of a wing. The rib portions may provide the aerodynamic profile of the wing, provide structural support for the wing skin(s) and provide support for compressive loads. The skin(s) may support torsional loads from the wing. The rib portions may connect between two attachment features and are connecting the two spar w ebs of the structure (i.e., connect the tw o spar webs via coupled to the attachment features). Each of the attachment features may include an opening 307 configured to receive a spar cap (see FIGS. 8-10) and may be coupled to each end of a spar w eb. For example, the spar web may have a first attachment feature coupled to a first end (e.g., a low er end) and a second attachment feature coupled to a second end (e.g., an upper end). In one or more embodiments, the four coupled / connected structures may include four spar caps inserted within and fixed to a corresponding attachment feature. For example, the spar cap may be fixed to the attachment feature via an adhesive, a screw, a nut and bolt, a rivet or other fastening device(s), where the spar caps may include carbon fibers combined with a resin or include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together and the attachment features may include metal such as an alloy or aluminum alloy. The carbon fibers or the dry carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. In one or more embodiments, each structure may include spar caps and thus, the four coupled / connected structures may include four spar caps. Each of the spar webs may include one or more apertures 308 and each of the rib portions may include one or more apertures 312. As illustrated in FIG. 3, each of the spar webs includes two apertures and each of the rib portions includes tw o apertures. The apertures may reduce the weight of the structure and provide routing of fluid and electrical lines and / or other systems for which need to be routed through / throughout the wing box substructure. Additionally or alternatively, an aperture (e.g., 308) in a spar web may be configured to receive and mount a propulsion device such as a propulsor. In one or more embodiments, theRef. No. <038191.01372>propulsion device may include an engine. Any of the connections may be a connection between the surfaces of the spar webs or one or more joints between the structures. The number and / or shape and / or size of the structures, rib portions, spar caps, spar webs, openings and apertures may be different from the number, shape and size illustrated in FIG. 3. For example, the number of rib portions and attachment features of a first structure and the shape of the openings and the first structure may be different from the number of rib portions and the attachment features of a second structure and the shape of the openings and the second structure. One or more of the structures may include a metal or an alloy, for example, an aluminum alloy structure. One or more of the structures may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure. The unitary structure may be formed by 3D printing such as laser bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E.

[0129] FIGS. 4-8 illustrate various structures illustrated without being coupled / connected to another structure. However, each of the single illustrated structures may be coupled / connected any one or more disclosed structures.

[0130] FIG. 4 illustrates an example structure 400 configured to be a portion of a wing box substructure. As illustrated in FIG. 4. the structure includes two spars webs 401 and 402, a plurality (i.e., four) rib portions 403, 404, 405, and 406 and a plurality (i.e., eight) of attachment features 407, 408, 409, 410, 411, 412, 413, and 414. The spars webs are configured to support shear forces resulting from loads originated from the aircraft structure. The rib portions may be configured to be attach to a skin of a wing. The rib portions may provide the aerodynamic profile of the wing, provide structural support for the wing skin(s) and provide support for compressive loads. The skin(s) may support torsional loads from the wing. Each of the attachment features may include an opening 417 configured to receive a spar cap (see FIGS. 8-10). Each of the attachment features may be coupled to a spar web and / or a rib portion. As shown in FIG. 4, each of the attachment features may be spaced apart (i.e., has a gap therebetween) from one another. However, in one or more embodiments, one or more of the attachment features may be spaced apart from one another and / or one or more of theRef. No. <038191.01372>attachment features may span the spar web. For example, two attachment features may span the spar web as shown in FIG. 6 and four attachment features may be spaced apart from one another as illustrated in FIG. 5. The structure may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure, and thus the spar webs, the attachment features and the rib portions are all integral and form the unitary structure. Thus, the rib portions illustrated in FIG. 4 may be, for example, upper and lower portions of a single element / rib. The unitary structure may be formed by 3D printing such as laser powder bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E. The structure may include a metal or an alloy, for example, an aluminum alloy structure. In one or more embodiments, structure 400 may be coupled / connected to one or more structures (e.g., structure 400) and / or one or more structures disclosed herein (e.g.. structures illustrated in FIGS. 2-9). For example, structure 400 may be connected to one or more of structures 400 and to one or more of the structures illustrated in FIGS. 2-9. The connected structures may include spar caps inserted within and fixed to a corresponding attachment feature. For example, the spar cap may be fixed to the attachment feature via an adhesive, a screw, a nut and bolt, a rivet or other fastening device(s). where the spar caps may include carbon fibers combined with a resin or include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together. The carbon fibers or the dry carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. The attachment features may include metal such as an alloy or aluminum alloy. The number and / or shape and / or size of the structure(s), rib portions, attachment features, spar caps, spar webs and openings may be different from the number, shape and size illustrated in FIG. 4. For example, the number of attachment features of a first structure and the shape of the openings and the first structure may be different from the number of the attachment features of a second structure and the shape of the openings and the second structure.

[0131] FIG. 5 illustrates an example structure 500 configured to be a portion of a wing box substructure. As illustrated in FIG. 5, the structure may include two sparsRef. No. <038191.01372>webs 501 and 502, two rib portions 503 and 504, two supports 515 and 516 and eight attachment features 506, 507, 508, 509, 510, 511. 512, and 513. The supports may be coupled (e.g., with four connecting members as shown in FIG.5) to the rib portions and configured to attach to a skin of a wing. The spars w ebs are configured to support shear forces resulting from loads originated from the aircraft structure. The rib portions may be configured to be attach to a skin of a wing. The rib portions may provide the aerodynamic profile of the wing, provide structural support for the wing skin(s) and provide support for compressive loads. The skin(s) may support torsional loads from the wing. Each of the attachment features may include an opening 514 configured to receive a spar cap (see FIGS.8-10). Each of the attachment features may be coupled to a spar web and / or a rib portion. As show n in FIG. 5, each of the attachment features may be spaced apart (i.e., has a gap therebetween) from one another. However, in one or more embodiments, one or more of the attachment features may be spaced apart from one another and / or one or more of the attachment features may span the spar web. For example, one attachment feature may span the spar web as shown in FIG. 6 and six attachment features may be spaced apart from one another as illustrated in FIG. 5. The structure may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure, and thus the spar webs, the attachment features, the supports and the rib portions are all integral and form the unitary structure. The unitary structure may be formed by 3D printing such as laser bed printing, for example, using a pow der bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E. The structure may include a metal or an alloy, for example, an aluminum alloy structure. In one or more embodiments, structure 500 may be coupled / connected to one or more structures (e.g., structure 500) and / or one or more structures disclosed herein (e.g., structures illustrated in FIGS. 2-9). For example, structure 500 may be connected to one or more of structures 500 and to one or more of the structures illustrated in FIGS. 2-9. The connected structures may include spar caps inserted within and fixed to a corresponding attachment feature. For example, the spar cap may be fixed to the attachment feature via an adhesive, a screw a nut and bolt, a rivet or other fastening device(s). where the spar caps may include carbonRef. No. <038191.01372>fibers combined with a resin or include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together. The carbon fibers or the dry carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. The attachment features may include metal such as an alloy or aluminum alloy. The number and / or shape and / or size of the structure(s), rib portions, attachment features, spar caps, spar webs, supports and openings may be different from the number, shape and size illustrated in FIG. 5. For example, the number of attachment features of a first structure and the shape of the openings and the first structure may be different from the number of the attachment features of a second structure and the shape of the openings and the second structure.

[0132] FIG. 6 illustrates an example structure 600 configured to be a portion of a wing box substructure. As illustrated in FIG. 6, the structure may include two spars webs 601 and 602, two rib portions 603 and 604, two supports 605 and 606 and four attachment features 607. 608, 609, and 610. Each of the spar webs may include one or more apertures 612, such as two apertures as illustrated in FIG. 6. The apertures may reduce the weight of the structure and provide routing of fluid and electrical lines and / or other systems for which need to be routed through / throughout the wing box substructure. The supports may be coupled (e.g.. with four connecting members as shown in FIG. 6) to the rib portions and configured to attach to a skin of a wing. The spars webs are configured to support shear forces resulting from loads originated from the aircraft structure. The rib portions may be configured to be attach to a skin of a wing. The rib portions may provide the aerodynamic profile of the wing, provide structural support for the wing skin(s) and provide support for compressive loads. The skin(s) may support torsional loads from the wing. Each of the attachment features may include an opening 611 configured to receive a spar cap (see FIGS. 8-10). Each of the attachment features may be coupled to a spar web and / or a rib portion. As shown in FIG. 6, each of the attachment features may span the spar web. However, in one or more embodiments, one or more of the attachment features may be spaced apart from one another and / or one or more of the attachment features may span the spar web. For example, two attachment features may span the spar web as shown in FIG. 6, or in contrast, four attachment features may be spaced apartRef. No. <038191.01372>from one another as illustrated in FIG. 5. The structure may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure, and thus the spar webs, the attachment features, the supports and the rib portions are all integral and form the unitary structure. The unitary structure may be formed by 3D printing such as laser powder bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E. The structure may include a metal or an alloy, for example, an aluminum alloy structure. In one or more embodiments, structure 600 may be coupled / connected to one or more structures (e.g., structure 600) and / or one or more structures disclosed herein (e g., structures illustrated in FIGS. 2-9). For example, structure 600 may be connected to one or more of structures 600 and to one or more of the structures illustrated in FIGS. 2-9. The connected structures may include spar caps inserted within and fixed to a corresponding attachment feature. For example, the spar cap may be fixed to the attachment feature via an adhesive, a screw, a nut and bolt, a rivet or other fastening device(s), where the spar caps may include carbon fibers combined with a resin or include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together. The carbon fibers or the dry carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. The attachment features may include metal such as an alloy or aluminum alloy. The number and / or shape and / or size of the structure(s), rib portions, attachment features, spar caps, spar webs, supports and openings may be different from the number, shape and size illustrated in FIG. 6. For example, the number of attachment features of a first structure and the shape of the openings and the first structure may be different from the number of the attachment features of a second structure and the shape of the openings and the second structure.

[0133] FIG. 7 illustrates an example structure 700 configured to be a portion of a wing box substructure. Example structure 700 may be the center structure of a plurality of connected structures of the wing box substructure. As illustrated in FIG. 7, the structure may include two spars webs 701 and 702, two rib portions 703 and 704, two supports 715 and 716, eight attachment features 706. 707, 708, 709. 710,Ref. No. <038191.01372>711, 712, and 713 and four couplings 705. The couplings are configured to provide attachment to an aircraft, for example, a fuselage. The couplings may include lugs having apertures or the couplings may be any device configured to provide connecting to a fuselage or other vehicle transport structure. The supports may be coupled (e.g., with four connecting members as shown in FIG.7) to the rib portions and configured to attach to a skin of a wing. The spars webs are configured to support shear forces resulting from loads originated from the aircraft structure. The rib portions may be configured to be attach to a skin of a wing. The rib portions may provide the aerodynamic profile of the wing, provide structural support for the w ing skin(s) and provide support for compressive loads. The skin(s) may support torsional loads from the wing. Each of the attachment features may include an opening 714 configured to receive a spar cap (see FIGS.8-10). Each of the attachment features may be coupled to a spar w eb and / or a rib portion. As shown in FIG. 7, each of the attachment features may be spaced apart (i.e., has a gap therebetween) from one another. However, in one or more embodiments, one or more of the attachment features may be spaced apart from one another and / or one or more of the attachment features may span the spar w eb. For example, two attachment features may span the spar web as shown in FIG. 6 and four attachment features may be spaced apart from one another as illustrated in FIG. 7. The structure may be a unitary (i.e.. formed as a single piece, not comprised of separate pieces fastened together) structure, and thus the spar webs, the attachment features, the supports, the couplings and the rib portions are all integral and form the unitary structure. The unitary structure may be formed by 3D printing such as laser bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E. The structure may include a metal or an alloy, for example, an aluminum alloy structure. In one or more embodiments, structure 700 may be coupled / connected to one or more structures (e.g., structure 700) and / or one or more structures disclosed herein (e g., structures illustrated in FIGS. 2-9). For example, structure 700 may be connected to one or more of structures 700 and to one or more of the structures illustrated in FIGS. 2-9. The connected structures may include spar caps inserted within and fixed to a corresponding attachmentRef. No. <038191.01372>feature. For example, the spar cap may be fixed to the attachment feature via an adhesive, a screw, a nut and bolt, a rivet or other fastening device(s), where the spar caps may include carbon fibers combined with a resin or include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together. The carbon fibers or the dry carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. The attachment features may include metal such as an alloy or aluminum alloy. The number and / or shape and / or size of the structure(s), rib portions, attachment features, spar caps, spar webs, supports, couplings and openings may be different from the number, shape and size illustrated in FIG. 7. For example, the number of attachment features of a first structure and the shape of the openings and the first structure may be different from the number of the attachment features of a second structure and the shape of the openings and the second structure.

[0134] FIG. 8 illustrates an example structure 800 with spar caps 803, 804, 805, and 806 fixed thereto and configured to be a portion of a wing box substructure. As illustrated in FIG. 8, the structure includes two spars webs 801 and 802, a plurality (i.e., two) rib portions 807 and 808 and aplurality (i.e., eight illustrated, only four labeled / numbered due to clarity of FIG. 8) of attachment features 809, 810, 811, and 812. The spars webs are configured to support shear forces resulting from loads originated from the aircraft structure. The rib portions may be configured to be attach to a skin of a wing. The rib portions may provide the aerodynamic profile of the wing, provide structural support for the wing skin(s) and provide support for compressive loads. The skin(s) may support torsional loads from the wing. Each of the attachment features may include an opening configured to receive a spar cap. Each of the attachment features may be coupled to a spar web and / or a rib portion. As shown in FIG. 8, each of the attachment features may be spaced apart (i.e., has a gap therebetween) from one another. However, in one or more embodiments, one or more of the attachment features may be spaced apart from one another and / or one or more of the attachment features may span the spar web. For example, two attachment features may span the spar web as shown in FIG. 6 and four attachment features may be spaced apart from one another as illustrated in FIGS. 5 and 8. The structure may be aRef. No. <038191.01372>unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure, and thus the spar webs, the attachment features and the rib portions are all integral and form the unitary structure. Thus, the rib portions illustrated in FIG. 8 may be, for example, upper and lower portions of a single element / rib. The unitary structure may be formed by 3D printing such as laser bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E. The structure may include a metal or an alloy, for example, an aluminum alloy structure. In one or more embodiments, structure 800 may be coupled / connected to one or more structures (e.g., structure 800) and / or one or more structures disclosed herein (e.g., structures illustrated in FIGS. 2-9). For example, structure 800 may be connected to one or more of structures 800 and to one or more of the structures illustrated in FIGS. 2-9. The spar caps may be inserted within and fixed to a corresponding attachment feature, and therefore, the spar caps may connect the structures together. For example, the spar cap may be fixed to the attachment feature via an adhesive, a screw, a nut and bolt, a rivet or other fastening device(s), where the spar caps may include carbon fibers combined with a resin or include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together. The carbon fibers or the dry carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. The attachment features may include metal such as an alloy or aluminum alloy. The number and / or shape and / or size of the structure(s), rib portions, attachment features, spar caps, spar webs and openings may be different from the number, shape and size illustrated in FIG. 8. For example, the number of attachment features of a first structure and the shape of the openings and the first structure may be different from the number of the attachment features of a second structure and the shape of the openings and the second structure.

[0135] FIG. 9 illustrates connected structures 900. More specifically, FIG. 9 illustrates two connected example structures 901 and 902 fixed to and connected together with spar caps 903, 904, 905, and 906, and configured to be a portion of a wing box substructure. As illustrated in FIG. 9, each of the tw o structures 901 and 902 may include two spars webs 907, 908, 909. and 910, two rib portions 911, 912,Ref. No. <038191.01372>913, and 914, two supports 915 and 916 (i.e., only one support for example, an upper support, is labeled / number in FIG. 9 for each structure for clarity but the other support for example, a lower support, is illustrated in FIG. 9 below the number support), and eight attachment features 917, 918, 919, 920, 924, 925, 925, and 927. Each of the spar webs may include one or more apertures 923. The apertures may reduce the weight of the structure and provide routing of fluid and electrical lines and / or other systems for which need to be routed through / throughout the wing box substructure. The supports may be coupled (e.g., with four connecting members as show n in FIG. 9) to the rib portions and configured to attach to a skin of a wing. The spars webs are configured to support shear forces resulting from loads originated from the aircraft structure. The rib portions may be configured to be attach to a skin of a wing. The rib portions may provide the aerodynamic profile of the wing, provide structural support for the wing skin(s) and provide support for compressive loads. The skin(s) may support torsional loads from the wing. Each of the attachment features may include an opening 922 configured to receive a spar cap. Each of the attachment features may be coupled to a spar web and / or a rib portion. As shown in FIG. 9, each of the attachment features may span the spar web. However, in one or more embodiments, one or more of the attachment features may be spaced apart from one another and / or one or more of the attachment features may span the spar web. For example, two attachment features may span the spar web as shown in FIGS. 6 and 9, and four attachment features may be spaced apart from one another as illustrated in FIG. 5. Each structure may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure, and thus the spar webs, the attachment features, the supports and the rib portions are all integral and form the unitary structure. The unitary structure may be formed by 3D printing such as laser bed printing, for example, using a pow der bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E. Each structure may include a metal or an alloy, for example, an aluminum alloy structure. In one or more embodiments, each structure may be coupled / connected to one or more structures (e.g., structure 901 and / or 902) and / or one or more structures disclosed herein (e.g., structures illustrated in FIGS. 2-9). ForRef. No. <038191.01372>example, each or both structures may be connected to one or more of structures 901 and / or 902 and to one or more of the structures illustrated in FIGS. 2-9. The structures may be connected at connection 921. For example, the two structures may be connected at the rib portions and the attachment features with an adhesive, a screw, a nut and bolt, a rivet or other fastening device(s). In one or more embodiments, a rib portion 914 of structure 902 may be connected to rib portion 912 of structure 901, and attachment features 917, 918, 919. and 920 of structure 902 may be connected to attachment features 924, 925, 925, and 927 of structure 901. In one or more embodiments, the two structures 901 and 902 may be formed as a unitary structure, and therefore the structures will not have connection 921 and there may be four attachment features and three rib portions. For example, structure 900 will be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure, and thus the spar webs, the attachment features, the supports and the rib portions are all integral and form the unitary structure. The unitary structure may be formed by 3D printing such as laser powder bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. The spar caps may be inserted within and fixed to a corresponding attachment feature. For example, the spar cap may be fixed to the attachment feature via an adhesive, a screw, a nut and bolt, a rivet or other fastening device(s), where the spar caps may include carbon fibers combined with a resin or include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together. The carbon fibers or the dry carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. The attachment features may include metal such as an alloy or aluminum alloy. The number and / or shape and / or size of the structure(s), rib portions, attachment features, spar caps, spar webs, supports and openings may be different from the number, shape and size illustrated in FIG. 9. For example, the number of attachment features of a first structure and the shape of the openings and the first structure may be different from the number of the attachment features of a second structure and the shape of the openings and the second structure.

[0136] FIG. 10 illustrates an aircraft wing 1000 formed of a plurality of structures 1001,1002, 1003, 1004. 1005, 1006, and 1007 connected together with a plurality’ ofRef. No. <038191.01372>spar caps 1008, 1009, and 1010. Due to the perspective view of the wing, FIG.10 illustrates three spar caps fixed within the three sets of attachment features. However, there are four spar caps in corresponding attached features, as disclosed and shown in FIGS. 2-9. One or more of the disclosed structures (e.g., disclosed structures of FIGS. 2-9) may the structures illustrated in FIG. 10, and the plurality of structures are connected together with spar caps and the spar caps are fixed to corresponding attachment features. The plurality of connected structures may span the length of the wing. Because the plurality of connected structures may span the length of the wing, the spar caps span the wing and provide tip-to-tip structural continuity, which eliminates or at least minimizes the number of bonded joints. Also, the wing may include a skin 1011 attached to one or more of the rib portions and / or supports of one or more structures. The number of connected structures may be more or less than the number illustrated in FIG. 10. The plurality of connected structures may not span the wing but may be a desired length of the wing. For example, the connected structures may form a length of 95% or 90% or 80% or 70% or 60% or 50% or any desired portion / percentage of the length of the wing.

[0137] FIG. 11 illustrates a front view (a), a side view (b) and a perspective view (c) of an example structure 1100 including a mount 1103 for an engine 1107. Any of the disclosed and illustrated structures (e.g., disclosed structures of FIGS. 2-10) may be structure 1100. The structure may include spar webs 1101, attachment features 1102, rib portions 1105, 1108, an engine mount 1103, and an opening 1104 configured to contain at least a portion of the engine. Each of the attachment features may include an attachment opening 1106 configured to contain a spar cap. FIG. 11 illustrates the structure configured to mount the engine in a lower portion of the structure, and thus, below the wing. However, the figure illustrates the structure may be configured to mount the engine in an upper portion or middle portion of the structure such that the engine may be mounted above the wing or through the wing. For example, in one or more embodiments, the structure may have the engine mount above the spar webs or attachment features such that the engine may be above the wing. In one or more embodiments, the structure may have the engine mount and opening in / thorough spar web such that the engine in / through the wing.Ref. No. <038191.01372>

[0138] FIG. 12 illustrates an example structure 1200 including an attachment feature 1202 containing a spar cap 1204, where the spar cap is within a cover 1205. FIG.12 illustrates a spar cap within a cover, which may be used with any of the disclosed and illustrated structures (e.g., disclosed structures of FIGS. 2-10). The structure may include spar webs 1201, attachment features 1202 and rib portions 1203. The spar caps may be inserted within and fixed to a corresponding attachment feature. For example, the spar cap may be fixed to the attachment feature via an adhesive, a screw, a nut and bolt, a rivet or other fastening device(s), where the spar caps may include carbon fibers combined with a resin or include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together. The carbon fibers or the dry carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. The spar cap may be within the cover, such that the cover may constrain (e.g., laterally constrain) the carbon fibers, and / or prevent the carbon fibers from buckling under axial compression and / or prevent galvanic corrosion between the structure / attachment feature and the spar cap. For example, if a sufficient force (e.g., axial force) is applied to the spar caps, the spar caps will tend to bow outward / buckle. However, the cover placed around the spar cap (e.g., the spar cap lies within the cover) may prevent and resist the bowing outward / buckling of the spar cap. Regarding the cover preventing galvanic corrosion, if the structure / attachment feature includes metal such as an aluminum alloy, the cover prevents the carbon fibers of the spar caps from contacting the metal structure / attachment feature, thus preventing galvanic corrosion between the structure / attachment feature and the spar cap. In one or more embodiments, the cover may include a plurality of apertures 1500 (see FIGS. 15 and 16). The plurality of apertures reduces the weight of the cover while maintaining the cover’s function of preventing the carbon fibers from buckling under axial compression. In one or more embodiments, the cover my include an elongated conduit, such that the conduit does not have holes therein except for at one end or both ends. In one or more embodiments, the cover may include a coating on its the external surface. For example, the cover may be metal, such as an aluminum alloy, and thus a non-metal coating may be on the external surface of the cover to prevent the metal cover from contacting the metalRef. No. <038191.01372>structure / attachment feature, thus preventing galvanic corrosion between the structure / attachment feature and the cover. The coating may include a ceramic coating, a polymeric coating, an adhesive (e.g., anon-metallic adhesive), a resin coating, a fiberglass coating or other coating / barrier preventing corrosion of the structure / attachment feature. Further details of the cover and clamping of the spar caps to prevent the spar caps from sliding within the structure / attachment feature are provided in the disclosure and example illustrations of FIGS. 13-16.

[0139] FIG. 13 illustrates an exploded view of an example cover 1301 configured to be secured / clamped to a spar cap 1300. More specifically, FIG. 13 illustrates a spar cap 1300, a cover 1301 configured to contain the spar cap, a fastener end clamp 1304 including a plurality of holes 1305, and an apparatus end clamp (e g., 1400, see FIGS. 14 and 16) including a clamp 1307 and an enclosure 1308. The cover may include a plurality of apertures 1500 (see FIGS. 15 and 16). The cover may include sleeves 1303 and 1306. The spar cap and cover may be any of the spar caps and covers described and illustrated within this disclosure. The fastener end clamp and the apparatus end clamp may be provided outside of the attached features of the structures to secure ends of the cover to the spar cap in order to prevent the spar caps from sliding within the structure / attachment feature. The fastener end clamp includes holes therein such that fastening devices such as screws or bolts and nuts may be provided within / through the holes and provide a clamping force between the fastener end clamp and the spar cap such that the fastener end clamp is secured to the spar cap. The fastener end clamp may be configured such that the fastener end clamp does not fit within the attachment features and thus, prevents the spar caps from sliding within the structure / attachment feature. The apparatus end clamp includes an enclosure encasing the clamp such that the apparatus end clamp provides a clamping force between the apparatus end clamp and the spar cap such that the apparatus end clamp is secured to the spar cap. The apparatus end clamp may be configured such that the apparatus end clamp does not fit within the attachment features and thus, prevents the spar caps from sliding within the structure / attachment feature. As illustrated in FIG. 13, clamp 1307 may include two diverging elements configured to fit within the enclosure and around the spar cap to apply a clamping force between the apparatus end clamp and the spar cap when the enclosure isRef. No. <038191.01372>fitted around the clamp. In one or more embodiments, the clamp may include more or less elements that shown in FIG. 13 or any of type of element(s) configured to provide a securing force between the apparatus end clamp and the spar cap. For example, clamp 1309 as shown in view (b) of FIG. 16 may be such a clamp that fits within the enclosure to secure the apparatus end clamp to the spar cap. FIG. 13 illustrates one fastener end clamp at a first end of the cover and one apparatus end clamp at a second end of the cover. However, each end of the cover may include the apparatus end clamp or each end of the cover may include the fastener end clamp. Optionally, there may be a sheath 1302 covering the spar cap. The sheath may prevent the carbon fibers from contacting the cover. The sheath may also prevent and / or resist the bowing outward / buckling of the spar cap. In one or more embodiments, if the cover is metal, the sheath prevents the carbon fibers of the spar cap from contacting the metal cover and may be a material that prevents galvanic corrosion between the carbon fibers and the cover, and consequentially prevents any type of corrosion of the structure / attachment feature. The sheath may include a ceramic, a polymer, an adhesive, a resin, fiberglass, graphite, or other material / barrier preventing corrosion of the structure / attachment feature.

[0140] FIG. 14 illustrates the example cover 1301 secured / clamped to the spar cap 1300.More specifically, FIG. 14 shows the apparatus end clamp 1400 and the fastener end clamp 1304 secured / clamped to the spar cap 1300, where the spar cap is within the cover 1301.

[0141] FIG. 15 illustrates details of the fastener end clamp 1304 securing the cover 1301 to the spar cap 1300. The fastener end clamp may abut sleeve 1303 of the cover as shown in views (a) and (b). However, the fastener end clamp may overlap the sleeve to provide a force to the sleeve / cover such that a clamping force is applied from the fastener end clamp between the sleeve / cover and the spar cap.

[0142] FIG. 16 illustrates details of an apparatus end clamp 1400 securing the cover 1301 to the spar cap 1300. The apparatus end clamp may include a single element clamp 1309 and enclosure 1308. The clamp of the apparatus end clamp may abut sleeve 1306 of the cover as shown in views (a) and (b). However, the enclosure of the apparatus end clamp may overlap the sleeve to provide a force to theRef. No. <038191.01372>sleeve / cover such that a clamping force is applied from the apparatus end clamp between the sleeve / cover and the spar cap.

[0143] FIGS. 17-20 illustrate various views of an aircraft wing structure including the structures / wing box substructure configured to be connected and connected with the spar caps.

[0144] FIG. 17 illustrates an exploded view of an aircraft wing structure 1710 including the structures / wing box substructure configured to be connected with the spar caps. More specifically, FIG. 17 illustrates a plurality of structures 1700 and a center structure 1701 configured to connected together with a plurality of spar caps 1702, 1703, 1704, and 1705 and configured to be within the skin of the aircraft wing structure, where the skin includes the upper skin 1706, the lower skin 1707 and the trailing edge skin 1708. The structures, wing box substructure and spar caps may be any of the structures, wing box substructures and spar caps disclosed and illustrated within this disclosure.

[0145] FIG. 18 illustrates the aircraft wing structure 1710 including the structures / wing box substructure connected with the spar caps. More specifically, FIG. 18 illustrates a plurality of structures 1700 and a center structure 1701 connected together with the plurality of spar caps 1702, 1703, 1704, and 1705 and configured to be within the skin of the aircraft wing structure, where the skin includes the upper skin 1706, the lower skin 1707 and the trailing edge skin 1708. The structures, wing box substructure and spar caps may be any of the structures, wing box substructures and spar caps disclosed and illustrated within this disclosure.

[0146] FIG. 19 illustrates the aircraft wing structure 1710 including a skin 1900, and the structures / wing box substructure connected with the spar caps positioned within the skin. More specifically, FIG. 19 illustrates a plurality of structures 1700 and a center structure 1701 connected together with the plurality7of spar caps 1702, 1703, 1704, and 1705 and positioned within the skin of the aircraft wing structure. The structures, wing box substructure and spar caps may be any of the structures, wing box substructures and spar caps disclosed and illustrated within this disclosure.

[0147] FIG. 20 illustrates the skin 1900 of the aircraft wing structure 1710 enclosing the structures / wing box substructure, which are / is connected by the spar caps. MoreRef. No. <038191.01372>specifically, FIG. 20 illustrates the plurality of structures 1700 connected together with the plurality of spar caps 1702, 1703, 1704, and 1705 and positioned within the skin of the aircraft wing structure. The structures, wing box substructure and spar caps may be any of the structures, wing box substructures and spar caps disclosed and illustrated within this disclosure.

[0148] Architecture of the aircraft in Figures 21-40

[0149] The disclosure and the example structures and systems, and process of assembling these example structures and systems of Figures 21-40 relate to apparatuses and systems including and methods of forming an architecture of a aircraft that provides versatility to the aircraft and enables a user to reconfigure and upgrade the aircraft depending on mission requirements and technology availability. More specifically, the aircraft’s structure / archi lecture may include a core fuselage system that may be combined with one or more partially or fully substitutable / interchangeable / modular structures and / or systems and hence is adaptable to different missions and improvements, such as technology improvements. Throughout this disclosure, the terms substitutable, interchangeable and modular are equivalently used and refer to structures, systems or structures of the system that may be swapped out for other systems or structures. For example, when a wing system is a substitutable / interchangeable / modular system, this means one wing may be swapped with another wing. More specifically, a wing system can includes multiple different wings, and the different wings can be substitutable / interchangeable / modular and thus, may be installed / coupled to a structure or system and the wing may also be removed from the structure or the system. A concept of this disclosure is a wing system, and / or a tail system and / or a container system and / or a landing gear system may be interchangeably coupled to a core fuselage structure / system or platform. The wing system may include one or more wings. The tail system may include one or more tails. The container system may include one or more containers. The landing gear system may include fixed or retractable landing gears systems. The landing gear system may include one or more wheel apparatuses.

[0150] An example of the above concept is, in a first mission configuration, a first wing may be interchangeably attached to a first structure of the core fuselage system,Ref. No. <038191.01372>a second wing may be interchangeably attached to a second structure of the core fuselage system, a tail / tail system may be interchangeably attached to a third structure of the core fuselage system, and first and second containers may be coupled together and interchangeably attached to the core fuselage system. However, due to a change in the mission of the aircraft, the first and second interchangeable wings are removed from the airplane and a new pair of interchangeable wings (e.g.. different from the removed first and second wings, where the new wings may be swept wings, longer or shorter wdngs, or wings having more or less engines, etc.). Because the new interchangeable wings are different from the removed first and second wings, the first and second structures of the core fuselage system may / are also removed, a new first structure and a new second structure are installed on the core fuselage system and the new interchangeable wings are respectively attached on these new first and second structures of the core fuselage system. The core fuselage system may contains avionics and other essential systems. Planform-wise, the architecture allows to have high span wings for greater efficiency or endurance or lower aspect ratio wings with more or less sweep for higher speeds and different propulsion systems may be used on the aircraft depending on the mission. For example, interchangeable propulsion systems may include distributed electric ducted fans spanning the wing or wing system and / or may include propulsors such as propeller engines or jet engines including turbofans, turbojets, turboprops, turboshafts, ramjets, scramjets, or other types of propulsors coupled to the aircraft. Propulsion systems or propulsors are only illustrated in some of Figures 21-40 to show one or more propulsors may be coupled to the aircraft such that the one or more propulsors may be positioned above the wing, below the wing or in / through the wing. However, the one or more propulsors or propulsion systems may be on the aircraft associated with Figures 21-40. Because the design / aircraft has high versatility and adaptability, the disclosed architecture may be used in both military and civilian applications.

[0151] Also, the high level of modularity may be enabled by the aircraft’s structure comprised of spar caps / booms (e.g., composite spar caps / booms) and structures / frames / modules. The spar caps and the structures / frames / modules may be made from a composite material or an alloy such as aluminum (Al) alloysRef. No. <038191.01372>or nickel (Ni) alloys. The spar caps and structures / frames / modules may be produced by three dimensional (3D) printing such as powder bed fusion using a PBF system, for example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E or other types of manufacturing methods. 3D printing of structures of the aircraft allows for the various structures to be produced quickly, in a desired location, to support diverse, changing and various missions, and enable easy integration of connectors and interfaces of the aircraft. An enabler of the modularity may be the use of electric propulsion. Electrical propulsion and the modular airframe structures / elements enabled the creation of new and interchangeable systems / modules such as new wings and new containers / pods (e g., a powerplant container / pod and a separate container / pod). For example, distributed electric propulsor(s) (DEP) (i.e., a propulsion system) may be provided over or under or through (or a combination thereof) the wing, and the wing and the propulsion system(s) may be interchangeable / modular. Hence the aircraft's core structure / system may only require to receive electrical power from a powerplant container / pod. In one or more embodiments, the powerplant container / pod may be coupled to the interchangeable core system at one or more interfaces and transmit to the interchangeable core system and / or the propulsion system forces and / or moments, and / or power (e.g., electrical power) and / or information, such signals (e g., control signals) for actuators, avionics, and other systems, etc. The disclosure may use distributed electric propulsors over, under or through (or a combination thereof) the wing. However, other powerplants and propulsion systems or other modular / interchangeable powerplants and propulsion systems may be used in the aircraft. The use of the containers / pods such as a powerplant container / pod and a separate container / pod is to carry cargo, ordnance, munitions, electronics or Intelligence, Surveillance and Reconnaissance (ISR) payloads, armament or other equipment unconstrained by fuselage dimensions. For example, the powerplant container / pod may be a self-contained enclosure / structure that inside may cany' power generating element(s). Inside the powerplant container / pod may include one or more batteries, other equipment and one or more generators, which may be powered by a powder source such as an internal combustion engine (ICE) or a turboshaft. The powerplantRef. No. <038191.01372>container / pod may also carry fuel and energy such as one or more batteries necessary for the mission of the aircraft. The powerplant container / pod may be connected / coupled / attached to the core fuselage structure / system by pins and lugs or hooks for the transfer of loads similar to external aircraft carriage such as external fuel tanks or external storage devices. Additionally, a separate container / pod may be connected / coupled to the powerplant container / pod and / or the core fuselage. The separate container / pod may be a self-contained enclosure / structure that inside may carry a payload, extra fuel and batteries, depending on the aircraft’s mission. Also, the separated container / pod may be connected / coupled / attached to the core fuselage structure / system by pins and lugs or hooks for the transfer of loads. The attachment of the powerplant container / pod and the separate container / pod may include connectors and may provide for the transfer of loads (e.g., carrying of the container / pods), the transfer of power (e.g., electrical / electricity) and the transfer of information (e.g., control signals for actuators, avionics, propulsors, systems, etc.). These connectors may be provided at interfaces (e.g., all interfaces) between containers, for example, betw een the powerplant container / pod and / or the separate container / pod and the core fuselage structure / system or between the core fuselage structure / system and the wings. Other aspects of the modularity of the aircraft may include retractable or fixed landing gear. For example, the landing gear may be modular and replaceable (i.e., interchangeably) attached to the core fuselage structure / system.

[0152] In terms of energy or powerplant for the aircraft, the aircraft is power-source agnostic. Hence, if a mission calls for low thermal and acoustic signatures, the aircraft, for example, may operate with batteries. For longer ranges, like ferrying, the aircraft, for example, may operate with electrical power generated from fossil fuels or other fuels. Also, a payload container / pod could be fully exchanged by an energy / powerplant container / pod. More details of the modular aircraft and the modular structure of the aircraft are shown in the below illustrations and are provided in the below disclosure.

[0153] FIG. 21 illustrates an aircraft 2100 having an architecture such that its systems, for example, wings, fuselage, nose, tail, landing gear, are interchangeable (i.e., substitutable / swapable / modular). More specifically, FIG. 21 illustrates a core system 2101 may have attached thereto an interchangeable tail system 2102, anRef. No. <038191.01372>interchangeable wing system 2103, an interchangeable propulsor 2107 attached to interchangeable wing 2105, an interchangeable propulsor 2108 attached to interchangeable wing 2104 or an interchangeable landing gear system 2019. FIG.21 illustrates the interchangeable landing gear system including two interchangeable front landing gear 2106 and two interchangeable rear landing gear 2106. The front and rear interchangeable landing gear of the interchangeable landing gear system may include fixed or retractable landing gear. However, Figures 21-40 may have the same quantity / number of interchangeable landing gear or more or less interchangeable landing gear coupled to the aircraft than the number illustrated in FIG. 21. FIG. 21 illustrates the interchangeable wing system includes two interchangeable wings. However, Figures 21-40 may have the same quantity / number of interchangeable wings or more or less interchangeable wings coupled to the aircraft than the number illustrated in FIG.21. FIG. 21 illustrates the interchangeable tail system include one interchangeable tail. However, Figures 21-40 may have one interchangeable tail or more interchangeable tails coupled to the aircraft than the number illustrated in FIG. 21. As disclosed above and will be shown and disclosed in more detail (e.g., when referencing FIGS. 21-40), an architecture of the aircraft 2100 provides versatility to the aircraft and enables a user to reconfigure and upgrade the aircraft depending on mission requirements and technology availability. More specifically, the aircraft’s structure / architecture may include one or more partially or fully substitutable / interchangeable / modular structures and / or systems such the interchangeable tail system 2102, the interchangeable wing system 2103, the interchangeable landing gear system 2019, the interchangeable propulsors 2107 and 2018 and a container system 2200 (see at least FIGS. 22 and 23). Hence the aircraft is adaptable to different missions and improvements, such as technology improvements.

[0154] FIG. 22 illustrates the aircraft 2100 having a container system 2200 coupled thereto. FIG. 22 illustrates the container system including two containers 2201 and 2202 coupled together and coupled to the aircraft’s core system 2101. Figures 21-40 may have the same quantity / number of interchangeable containers or more or less interchangeable containers coupled to the aircraft than the number illustrated in FIG. 22. More details of the container system and the containersRef. No. <038191.01372>will be provided in more detail later due to how the containers are coupled to the structure of the interchangeable core system.

[0155] FIG. 23 illustrates skins separated from the aircraft’s core system 2101, for the purpose of illustration, and the container system 2200 including the two containers 2201 and 2202 configured to be coupled together and coupled to the core system. The core system 2101 may include amain structure 2203, aforward tip structure 2204 and a rear tip structure 2205. The aircraft may include a skin including an upper main skin 2207, a lower main skin 2210, an upper forward tip skin 2206, a lower forward tip skin 2211, an upper rear tip skin 2208 and a lower rear tip skin 2209. The aircraft skin may also include skins attached to the one or more wings and tails. More details of the structures of the core system will be provided later in associated detailed views of these core system structures.

[0156] FIG. 24 illustrates two different aircraft 2100 configurations (e.g., the aircraft of FIGS. 21-40) based on the same core system 2101, each having different type, mounting and number of propulsors. The left aircraft in FIG. 24 illustrates three jet engine propulsors 2400 mounted above wing 2105 and three jet engine propulsors 2401 mounted above wing 2104. The right aircraft in FIG. 24 illustrates one propeller propulsor 2402 mounted below wing 2105 and one propeller propulsor 2403 mounted below wing 2104. However, any of the aircrafts (e.g., aircraft of Figures 21-40) may have the same quantity / number of interchangeable propulsors or more or less interchangeable propulsors than the number illustrated in FIG. 24.

[0157] FIGS. 25 and 26 illustrates detailed views of the aircraft’s core system 2101 and the wing (e.g., wing 2105) coupled to the aircraft’s core system. Also, FIGS. 25- 36 illustrate various details of and various processes of forming the aircraft’s core system. The core fuselage structure 2101 may include a main structure 2203, a forward tip structure 2204 and a rear tip structure 2205. The main fuselage structure 2203 may include a front structure 2500, which may be referred to as a center wing box, an aft structure 2503, an intermediate structure 2502 and a frame structure 2501 (e.g., pod / container frame structure). As illustrated in FIG.25, four core booms 2504 are fixed to and connect together the front structure, the frame structure, the intermediate structure and the aft structure. Also, fourRef. No. <038191.01372>front booms 2505 are fixed to and connect together the front structure and the forward tip structure. For example, the four front booms are fixed to the front structure and nose structure 2508 of the forward tip structure. Additionally, four rear booms 2506 are fixed to and connect together the aft structure and the rear tip structure. For example, the four rear booms 2506 are fixed to the aft structure and a tail structure 2507 of the rear tip structure. The front landing gear 2106 may be coupled to the forward structure 2500 and the rear landing gear 2106 may be coupled to the aft structure 2503. For example, each of the front landing gear 2106 may be coupled to outward structures of the front structure and the each of the rear landing gear may be coupled to outward structures of the aft structure. The structures of the core fuselage structure may be produced by 3D printing such as powder bed fusion or other types of manufacturing methods.

[0158] The front structure 2500 may include a plurality of structures 2600, 2601, 2602, and 2603 (see FIG. 26) coupled / fixed together via upper front structure booms 2509 and 2510 and lower front structure booms 2511 and 2512. The plurality’ of structures of the front structure may include a starboard outboard structure (e.g., 2601) having a front landing gear attachment, a port outboard structure (e.g., 2600) having a landing gear attachment, a starboard inboard structure (e.g., 2602) and a port inboard structure (e.g., 2603). However, there may be more or less structures that make up the front structure than shown in the figures. Each of the structures of the front structure are capable of supporting bending, shear and torsion loads and one or more of the structures of the front structure may include an attachment lug 2513 and 2514 configured to couple to one or more containers 2201 and 2202 such as the powerplant container and / or the separate container. Also, each of the structures of the front structure may include one or more apertures / slots (e.g., slots 2700, 2701, 2702, and 2703 in FIG. 27) configured to connect to and / or bond to a corresponding boom of the upper and lower front structure booms. Additionally, each of the structures of the front structure may include one or more apertures / slots (e.g., slots 2800 and 2801 in FIG. 28) configured to connect to and / or bond to a corresponding boom of the core booms. The apertures / slots may be in a square or rectangular shape or any other geometric shape. The upper and lower front structure booms provide a connection between and to the structures of the front structure. The upper andRef. No. <038191.01372>lower front structure booms and the core booms may be in a square or rectangular shape or any other geometric shape configured to be inserted into the apertures / slots of the structures. The upper and lower front structure booms and the core booms may be made from a composite material or an alloy such as aluminum (Al) alloys or nickel (Ni) alloys. In one or more embodiments, the composite material may include carbon fibers combined with a resin. In one or more embodiments, the composite material may include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together. The carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. Optionally, the plurality of structures of the front structure may additionally be connected together with one or more fastening features and / or bonding elements such as an adhesive. For example, one or more of the plurality of structures of the front structure may include connecting features for the structures to connect to one another. The connecting features may include a protrusion / tongue and / or a recess / groove. For example, a first structure may include a protrusion at a first region thereof and the protrusion may be configured to be coupled to a recess of a second structure. The first structure may also include a recess or protrusion in a second region thereof and the recess or protrusion is configured to be coupled to a protrusion or recess of the second structure or a protrusion or recess of a third structure. An adhesive may be included with the connecting feature(s). For example, the adhesive may be in a recess or on a protrusion of the structure to couple the structures together. In one or more embodiments, the front structure may include a single structure including apertures / slots configured to receive and connect / bond with corresponding upper and lower front structure booms. The structures of the front structure may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure. The unitary structure may be formed by 3D printing such as laser bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1 A-1E. The structure may include a metal or an alloy, for example, an aluminum alloy structure.Ref. No. <038191.01372>

[0159] The frame structure 2501 may include a plurality of structures coupled / fixed (e.g.. connected via fastening and / or bonding) together and are capable of supporting bending, shear and torsion loads. The plurality of structures of the frame structure may include a starboard frame structure (e.g., 2604 in FIG. 26), a port frame structure (e.g., 2604 in FIG. 26) and two inner frame structures (e.g., 2606 and 2607 in FIG. 26). However, there may be more or less structures that make up the frame structure than shown in the figures. One or more of the structures of the frame structure may include an attachment lug 2515 and 2516 configured to couple to one or more containers 2201 and 2202 such as the powerplant container and / or the separate container. Optionally, the starboard frame structure and / or the port frame structure may have a landing gear attachment. Also, each of the structures of the frame structure may include one or more apertures / slots (e.g., slots 3400, 3401, 3402, and 3403 in FIG. 34) configured to connect to and / or bond to a corresponding boom of the core booms. Each of the core booms may be fixed / coupled to a corresponding slot in the one or more of the structures of the frame structure via one or more fasteners / fastening devices and / or bonded via an adhesive. The apertures / slots may be in a square or rectangular shape or any other geometric shape. The core booms provide a connection to and / or between the structures of the frame structure and may be in a square or rectangular shape or any other geometric shape configured to be inserted into the apertures / slots of the structures. In one or more embodiments, the frame structure may include a single structure. The single structure may include apertures / slots configured to receive and connect / bond with corresponding booms. Optionally, the plurality of structures of the frame structure may additionally be connected together with one or more connecting / fastening features and / or bonding elements such as an adhesive. The connecting features may include a protrusion / tongue and / or a recess / groove. For example, a first structure may include a protrusion at a first region thereof and the protrusion is configured to be coupled to a recess of a second structure. An adhesive may be included with the connecting feature(s). The first structure may also include a recess or protrusion in a second region configured to be coupled to a protrusion or recess of the second structure. The structures of the frame structure may be a unitary (i.e., formed as a single piece, not comprised ofRef. No. <038191.01372>separate pieces fastened together) structure. The unitary structure may be formed by 3D printing such as laser bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E. The structure may include a metal or an alloy, for example, an aluminum alloy structure.

[0160] The intermediate structure 2502 may include a plurality of structures coupled (e.g., connected via fastening and / or bonding) together and are capable of supporting bending, shear and torsion loads. The plurality of structures of the intermediate structure may include a starboard intermediate structure (e.g., 2519), a port intermediate structure (e.g., 2517) and an inner intermediate structure (e.g., 2518). However, there may be more or less structures that make up the intermediate structure than shown in the figures. For example, each of the plurality of structures of the intermediate structure may include connecting features for the structures to connect to one another. The connecting features may include a protrusion / tongue and / or a recess / groove. For example, a first structure may include a protrusion at a first region thereof and the protrusion is configured to be coupled to a recess of a second structure. The first structure may also include a recess or protrusion in a second region configured to be coupled to a protrusion or recess of the second structure. One or more of the structures of the intermediate structure may have a landing gear attachment. One or more of the structures of the intermediate structure may include an attachment jug 2520 configured to couple to the one or more containers such as the powerplant and separate containers. Also, each of the structures of the intermediate structure may include one or more apertures / slots (e.g., slots 3300, 3301, 3302, and 3304) configured to connect to and / or bond to a corresponding core boom. The apertures / slots may be in a square or rectangular shape or any other geometric shape. The core booms provide a connection to and / or between the structures of the intermediate structure and may be in a square or rectangular shape or any other geometric shape configured to be inserted into the apertures / slots of the structures. In one or more embodiments, the intermediate structure may include a single structure including apertures / slots configured to receive and connect / bond with corresponding booms. Optionally, the plurality of structuresRef. No. <038191.01372>of the intermediate structure may additionally be connected together with one or more connecting / fastening features and / or bonding elements such as an adhesive. The connecting features may include a protrusion / tongue and / or a recess / groove. For example, a first structure may include a protrusion at a first region thereof and the protrusion is configured to be coupled to a recess of a second structure. The first structure may also include a recess or protrusion in a second region configured to be coupled to a protrusion or recess of the second structure. An adhesive may be included with the connecting feature(s). The structures of the intermediate structure may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure. The unitary structure may be formed by 3D printing such as laser bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS.1A-1E. The structure may include a metal or an alloy, for example, an aluminum alloy structure.

[0161] The aft structure 2503 may include a plurality of structures coupled (e.g., connected via fastening and / or bonding) together and are capable of supporting bending, shear and torsion loads. The plurality of structures of the aft structure may include a aft starboard structure (e g., 3202 in FIG. 32), a aft port structure (e.g.. 3203 in FIG. 32) and two aft inner structures (e.g., 3200 and 3201 in FIG.32). However, there may be more or less structures that make up the aft structure than show n in the figures. Optionally, each of the starboard and port structures of the aft structure may have a landing gear attachment. Optionally, one or more of the structures of the aft structure may include an attachment lug configured to couple to one or more containers 2201 and 2202 such as the powerplant container and / or the separate container. Optionally, each of the plurality of structures of the aft structure may include connecting features for the structures to connect to one another. An adhesive may be included with the connecting feature(s). The connecting features may include a protrusion / tongue and / or a recess / groove. For example, a first structure may include a protrusion at a first region thereof and the protrusion is configured to be coupled to a recess of a second structure. The first structure may also include a recess or protrusion in a second region configured to be coupled to a protrusion or recess of the second structure. Also,Ref. No. <038191.01372>one or more of the structures of the aft structure may include one or more apertures / slots (e.g.. slots 3204 and 3205 in FIG. 32) configured to connect to and / or bond to a corresponding boom. The apertures / slots may be in a square or rectangular shape or any other geometric shape. The booms provide a connection to and / or between the structures of the aft structure and may be in a square or rectangular shape or any other geometric shape configured to be inserted into the apertures / slots of the structures. In one or more embodiments, the aft structure may include a single structure including apertures / slots configured to receive and connect / bond with corresponding booms. The structures of the aft structure may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure. The unitary structure may be formed by 3D printing such as laser bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E. The structure may include a metal or an alloy, for example, an aluminum alloy structure.

[0162] The forward tip structure 2204 may include the front booms 2505 and the nose structure 2508. The nose structure may include a single structure or a plurality of structures capable of supporting bending, shear and torsion loads. The nose structure may include a metal or an alloy, for example, an aluminum alloy structure. The nose structure may include an attachment lug 2523 configured to couple to the one or more containers such as the powerplant and separate containers. The nose structure may include one or more apertures / slots 2521 and 2522 configured to connect to and / or bond to a corresponding boom of the front booms 2505. The apertures / slots may be in a square or rectangular shape or any other geometric shape. The front booms provide a connection between the nose structure and the front structure and may be in a square or rectangular shape or any other geometric shape configured to be inserted into the apertures / slots of the nose structure. The booms may be made from a composite material or an alloy such as aluminum (Al) alloys or nickel (Ni) alloys. In one or more embodiments, the composite material may include carbon fibers combined with a resin. In one or more embodiments, the composite material may include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together. The carbon fibers may include unidirectional carbon fibers. The unidirectionalRef. No. <038191.01372>carbon fibers may be aligned in a direction of a force applied thereto. The nose structure or each of the structures of the nose structure may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure. The unitary structure may be formed by 3D printing such as laser bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the powder bed fusion system may be the PBF system 100 discussed and illustrated in FIGS. 1A-1E. The structure may include a metal or an alloy, for example, an aluminum alloy structure.

[0163] The rear tip structure 2205 may include the rear booms 2506 and the tail structure 2507. The tail structure may include a single structure or a plurality of structures capable of supporting bending, shear and torsion loads. The tail structure may include a metal or an alloy, for example, an aluminum alloy structure. Optionally, the tail structure may include an attachment configured to couple to the one or more containers such as the powerplant and separate containers. The tail structure may include one or more apertures / slots (e.g., slots 3500 and 3501 in FIG. 35) configured to connect to and / or bond to a corresponding rear boom of the rear booms 2506. The apertures / slots may be in a square or rectangular shape or any other geometric shape. The front booms provide a connection between the tail structure and the aft structure and may be in a square or rectangular shape or any other geometric shape configured to be inserted into the apertures / slots of the tail structure. The rear booms may be made from a composite material or an alloy such as aluminum (Al) alloys or nickel (Ni) alloys. In one or more embodiments, the composite material may include carbon fibers combined with a resin. In one or more embodiments, the composite material may include dry carbon fibers (i.e., carbon fibers not combined with a resin) bundled together. The carbon fibers may include unidirectional carbon fibers. The unidirectional carbon fibers may be aligned in a direction of a force applied thereto. The tail structure or each of the structures of the tail structure may be a unitary (i.e., formed as a single piece, not comprised of separate pieces fastened together) structure. The unitary structure may be formed by 3D printing such as laser bed printing, for example, using a powder bed fusion (PBF) system or other AM systems. For example, the pow der bed fusion system may be the PBF system 100Ref. No. <038191.01372>discussed and illustrated in FIGS. 1A-1E. The structure may include a metal or an alloy, for example, an aluminum alloy structure.

[0164] FIGS. 27-31 illustrate details and assembly of the front structure.

[0165] The views in FIG. 27 show an example structure (e.g., starboard inner structure 2602) of the front structure 2500, where the lower front structure booms 2511 and 2512 and positioned within the slots 2700 and 2701 of the example structure such that the lower front structure booms are to be fixed to the slots. For example, the example structure may be lowered onto the lower front structure booms.

[0166] FIG. 28 illustrates a side view the example structure 2602 showing the lower front structure booms 2511 and 2512 positioned within the slots 2700 and 2701 of the example structure. FIG. 28 also illustrates the booms and a corresponding slot may be in the shape of a rectangle / square or a circle.

[0167] FIG. 29 illustrates the lower front structure booms 2511 and 2512 being positioned and positioned within the slots of the example structures 2600, 2601, 2602, and 2603 of the front structure 2500 such that the lower front structure booms are to be fixed to the slots. For example, the example structures may be lowered such that each of the two slots of each structures has a corresponding lower front structure boom therein.

[0168] FIG. 30 illustrates upper front structure booms 2509 and 2510 being positioned and positioned within slots of the example structures of the front structure 2500 such that the upper front structure booms are to be fixed to the slots. For example, the upper front structure booms may be lowered into the slots of the example structures.

[0169] FIG. 31 illustrates a side view the example structure 2602 showing the upper and lower front structure booms positioned within the slots of the example structure.

[0170] FIGS. 32-35 illustrate details and assembly of the core structure.

[0171] FIG. 32 illustrates the assembled front structure 2500 and the aft structure 2503 being positioned and positioned on the core beams. For example, the assembled front structure 2500 and the aft structure 2503 may be lowered onto two of the core beams.

[0172] FIG. 33 illustrates in addition to the assembled front structure 2500 and the aft structure 2503 being positioned and positioned on the core beams, the structures (e.g.. 2517, 2518, and 2519) of the intermediate structure 2502 being positionedRef. No. <038191.01372>on the core beams. For example, the three structures of the intermediate structure may be lowered and two of the three structures have slots into which two of the core beams are inserted therein.

[0173] FIG. 34 illustrates the four core beams inserted within corresponding slots of the assembled front structure 2500, the aft structure 2503, the intermediate structure 2502 and the frame structure 2502. FIG. 34 also illustrates the structures (e.g., 2605, 2605, 2606. and 2607) of the frame structure 2501 being positioned (e.g.., slid onto) onto two lower core beams 2504. FIG. 34 illustrates the front structure, the aft structure, the intermediate structure and the frame structure assembled on the four core beams and thus, forming the complete main structure 2203.

[0174] FIG. 35 illustrates details and assembly of the forward tip structure 2204 and the rear tip structure 2205, where the forward tip structure is connected to the front structure 2500 and the rear tip structure is connected to the aft structure 2503 such that the interchangeable core system 2101 is formed. For example, the four front booms 2505 are connected / fixed to corresponding slots of the nose structure 2505 and the structures of the front structure. Also, the four rear booms 2506 are connected / fixed to corresponding slots of the tail structure 2507 and the structures of the aft structure.

[0175] FIG. 36 illustrates four landing gear 2106 configured to be coupled to the front structure 2500 and the aft structure 2503. For example, one (e.g., a first) of the two front landing gear may be attached to and removed from a port outboard structure (e.g., 2600) of the front structure, another (e.g., a second) of the two front landing gear may be attached to and removed from a starboard outboard structure (e.g.. 2601) of the front structure, one (e.g., a third) of the two rear landing gear may be attached to and removed from an aft port structure (e.g., 3203) of the aft structure, and another (e.g., a fourth) of the two rear landing gear may be attached to and removed from an aft starboard structure (e.g., 3202). The four landing gear 2106 form the landing gear system 2109 and FIG. 36 shows a view of the landing gear system 2109 coupled to the core system 2101.

[0176] FIG. 37 illustrates an example of a wing 3700 of the wing system 2103. The wing may include a plurality of structures, and may be similar to the wing illustrated in FIG. 10. The plurality of structures may be the same or differ from the plurality of structures illustrated in FIGS. 2-20. For example, wing 3700 may include aRef. No. <038191.01372>plurality of structures 3702 and 3703 (also see FIG. 26) connected together with a plurality of spar caps 3701 and 2609( also see FIG. 26). The wing may be covered with a skin. The skin may include an upper skin 3705, the lower skin 3704 and the trailing edge skin 3706. The spar caps may include / made from the material disclosed in the spar caps in FIGS. 2-20. In one or more embodiments, the plurality of structures 3702 and 3703 may differ from the structures illustrated in FIGS. 2-20 in that the plurality of spar caps 3701 may be inserted into and fixed to slots (2608 in FIG. 26 or slots 2701 as illustrated in FIG. 28) of the structures, rather than the attachment features illustrated in FIGS. 2-9. However, the plurality of spar caps 3701 may be inserted into and fixed to attachment features illustrated in FIGS. 2-9. Also, the spar caps 3701 of wing 3700 may extend into and are fixed to the slots of the structures of the front structure.

[0177] FIG. 38 illustrates the wings 2104 and 2105 of the wing system 2103 configured to connect to the front structure 2500. For example, the spar caps of one wing are inserted into and fixed to slots or attachment features of the outer port structure of the front structure, and the spar caps of the other wing are inserted into and fixed to slots or attachment features of the outer starboard structure of the front structure. The right view in FIG. 38 illustrates the two wings connected to the front structure 2500.

[0178] FIG. 39 illustrates an exploded view' of the skins to be attached to the aircraft and a view' of the skin attached to the aircraft. The aircraft 2100 may include a skin including an upper main skin 2207, a lower main skin 2210, an upper forward tip skin 2206, a lower forward tip skin 2211. an upper rear tip skin 2208 and a lower rear tip skin 2209. The right view of FIG. 39 also illustrates an aircraft skin includes skins attached to the w'ings.

[0179] FIG. 40 illustrates example views of the two containers 2201 and 2202 configured to be coupled together and coupled together and coupled to the aircraft 2100. FIG. 40 illustrates two containers 2201 and 2202 of the container system 220 configured to be coupled to each other and to the aircraft. The right view' of FIG. 40 illustrates the tw'O containers 2201 and 2202 connected together forming the container system 220 and the two containers coupled to the aircraft.Ref. No. <038191.01372>

[0180] In various embodiments, the core fuselage structure may include one or more wings. For example, the core fuselage structure may include two wings, where a first wing may be attached to a first side (e.g., the starboard outboard structure) of the front structure and a second wing may be attached to a second side (e.g., the port outboard structure) of the front structure. Each wing may include one or more propulsion wing frames / structures and / or one or more wing frames / structures. The one or more wing frames may be poisoned further away from the main fuselage structure than the one or more propulsion wing frames. The one or more propulsion wing frames may be connected together and one or more wing frames may be connected together. Also, a wing frame may be connected to a propulsion wing frame. Each of the one or more propulsion wing frames and the one or more wing frames may include one or more apertures / slots configured to connect to and / or bond to a corresponding boom. Each of the corresponding booms may also connect to and / or bond to a structure (e.g., the starboard outboard structure, the port outboard structure) of the front structure. The apertures / slots may be in a square or rectangular shape or any other geometric shape. The booms provide a connection to and / or between the one or more propulsion wing frames and the one or more wing frames and may be in a square or rectangular shape or any other geometric shape configured to be inserted into the apertures / slots of the one or more propulsion wing frames and the one or more wing frames. The booms may be made from a composite material or an alloy such as aluminum (Al) alloys or nickel (Ni) alloys. Optionally, the one or more propulsion wing frames may additionally be connected together with one or more fastening features and / or bonding elements such as an adhesive. Also optionally, the one or more wing frames may additionally be connected together with one or more fastening features and / or bonding elements such as an adhesive. For example, each of one or more propulsion wing frames and / or the one or more wing frames may include connecting features for the frames to connect to one another. The connecting features may include a protrusion / tongue and / or a recess / groove. For example, a first frame (i.e., propulsion wing frame and / or wing frame) may include a protrusion at a first region configured to be coupled to a recess of a second frame. The first frame may also include a recess or protrusion in a second region configured to be coupled to a protrusion or recessRef. No. <038191.01372>of the second frame or a protrusion or recess of a third frame. An adhesive may be included with the connecting feature(s). For example, the adhesive may be in a recess or on a protrusion of the frame to couple the frames together.

[0181] In various embodiments, the core fuselage structure may include one or more the tails. For example, the core fuselage structure may include one tail attached via one or more lugs and / or other connecting devices to one or more structures of the aft structure and the rear tip structure.

[0182] Skin(s) may be adhesively bonded or fastened to the core fuselage structure. The skins may or may not contribute to the overall structural loads. The skins may provide the aerodynamic profde for the aircraft. Depending on the core fuselage structure, additional frames may be needed to support the skins and installed like the previous structures of the aircraft.

[0183] More details of assembling and methods of forming the modular structure of the aircraft are shown in the below illustrations and are provided in the below disclosure. The assembling of and methods of forming the modular structure of the aircraft may include / incorporate the disclosure of the above apparatuses and structures within the various embodiments.

[0184] Front Structure

[0185] Each of the structures of the front structure (i.e.. the center wing box) may include a plurality (e.g., two lower and two upper apertures / slots oriented transverse to the axial direction (i.e., front to aft direction) of the main fuselage structure as shown in the below illustrations) of lower apertures / slots and upper apertures / slots formed within the structures and oriented transverse to the main fuselage structure. The structures, individually or in combination, may be lowered / positioned and / or raised / positioned such that corresponding booms are slid / positioned within the apertures / slots. In one example, the structures may be positioned such that the booms may be slid into each of the apertures / slots. In another example, the structures may be lower / positioned such that the booms are positioned within the lower slots and the booms may be slid into the upper slots or the structures are raised / positioned such that the corresponding booms may be within the upper slots. The booms may be fastened or bonded to the lower slots before or after the structures are raised / positioned such that the corresponding booms are within the upper slots. In another example, the structures may beRef. No. <038191.01372>positioned or raised such that the booms are positioned within the upper slots and the booms may be slid into the lower slots or the structures are lowered / positioned such that the corresponding booms may be within the lower slots. The slots may be formed with a void within the side where the corresponding booms are able to be inserted / positioned / low ered / raised within slots. The booms may be connected to and / or bonded to the structures, thus connecting the structures of the front structure together. For example, an adhesive may be applied within the slots to bond the booms to the structures and / or a fastener or other joining device(s) may connect the booms to the structures. The booms may be fixed to a jig or held by one or more robots such the robot(s) slide / position the booms within the slots of the structures. Each of the structures of the front structure may be formed / produced by 3D printing such as powder bed fusion or other types of manufacturing methods. The booms and structures may be made from a composite material or an alloy such as aluminum (Al) alloys or nickel (Ni) alloys.

[0186] Front Structure, Aft Structure and Intermediate Structure

[0187] Each of the structures of the front structure, the aft structure and the intermediate structure may include a plurality7(e.g., two lower and two upper apertures / slots oriented along the axial direction (i.e., front to aft direction) of the main fuselage structure as shown in the below illustrations) of lower apertures / slots and upper apertures / slots formed within the structures and oriented along the axial direction of the main fuselage structure. The structures of the front structure, the aft structure and the intermediate structure, individually and / or in combination, may¬ be lowered / positioned and / or raised / positioned such that the corresponding booms are slid / positioned within apertures / slots. In one example, the structures may be positioned such that the booms may be slid into each of the apertures / slots. In another example, the structures may be low er / positioned such that the booms are positioned within the lower slots and the booms may be slid into the upper slots or the structures are raised / positioned such that the corresponding booms may be within the upper slots. In another example, the booms may be slid / positioned within slots of the front structure and the aft structure, then the booms may be slid / positioned within slots of the intermediate structure. The booms may be fastened or bonded to the lower slots before or afterRef. No. <038191.01372>the structures are raised / positioned such that the corresponding booms are within the upper slots. In another example, the structures may be positioned or raised such that the booms are positioned within the upper slots and the booms may be slid into the lower slots or the structures are lowered / positioned such that the corresponding booms may be within the lower slots. The slots may be formed with a void within the side where the corresponding booms are able to be inserted / positioned / lowered / raised within the apertures / slots. The booms may be connected to and / or bonded to the structures, thus connecting the structures of the front structure, the aft structure and the intermediate structure together. For example, an adhesive may be applied within the slots to bond the booms to the structures and / or a fastener or other joining device(s) may connect the booms to the structures. The booms may be fixed to a jig or held by one or more robots such the robot(s) slide / position the booms within the slots of the structures. Each of the structures may be formed / produced by 3D printing such as powder bed fusion or other types of manufacturing methods. The booms and structures may be made from a composite material or an alloy such as aluminum (Al) alloys or nickel (Ni) alloys.

[0188] Pod Frame

[0189] Each of the plurality of structures (e.g., four structures as shown in the below illustrations) of the pod frame may include connecting features for the structures to connect to one another and to connect to the booms, which connect the front structure, the aft structure and the intermediate structure together (i.e., the booms oriented along the axial direction of the main fuselage structure). The connecting features may include a protrusion / tongue and / or a recess / groove. For example, a first structure may include a protrusion or recess at a first region configured to be coupled to a recess or protrusion of a second structure. The first structure may also include another recess or protrusion in a second region configured to be coupled to another protrusion or recess of the second structure. An adhesive may be applied in one or more of the recesses to connect with a corresponding protrusion and thus fix the structures together. Also, each of the structures of the pod frame may be attached (e.g., via one or more fasteners / fastening devices) and / or bonded (e.g., via an adhesive) to the booms and / or may include one or more apertures / slots configured to connect to and / or bond to a correspondingRef. No. <038191.01372>boom. The structures may be slid / positioned together and coupled to the booms to form the pod frame. For example, the structures may be slid horizontally to connect together and to the booms. The apertures / slots may be in a square or rectangular shape or any other geometric shape. The slots may be formed with a void within the side where the corresponding booms are able to be inserted / positioned / lowered / raised within the slots. The booms provide a connection to the structures of the pod frame and may be in a square or rectangular shape or any other geometric shape configured to be inserted into the apertures / slots of the structures. For example, an adhesive may be applied within the slots to bond the booms to the structures and / or a fastener or other joining device(s) may connect the booms to the structures. The booms may be fixed to a jig or held by one or more robots such the robot(s) slide / position the booms within the recesses / slots of the structures. Each of the structures may be formed / produced by 3D printing such as powder bed fusion or other types of manufacturing methods. The booms and structures may be made from a composite material or an alloy such as aluminum (Al) alloys or nickel (Ni) alloys.

[0190] Forward Tip structure and Rear Tip Structure

[0191] Each of the structures of the forward tip structure and the rear tip structure may include a plurality (e.g., two lower and two upper apertures / slots oriented along the axial direction (i.e., front to aft direction) of the main fuselage structure as shown in the below illustrations) of lower apertures / slots and upper apertures / slots formed within the structures and oriented along the axial direction of the main fuselage structure. The structures of the forward tip structure and the rear tip structure, individually and / or in combination, may be lowered / positioned and / or raised / positioned such that the corresponding booms are slid / positioned within apertures / slots. The booms may be the booms connecting the front structure, the aft structure and the intermediate structure together or may be separate / additional booms from the booms connecting the front structure, the aft structure and the intermediate structure together. In one example, the structures may be positioned such that the booms may be slid into each of the apertures / slots. In another example, the structures may be lower / positioned such that the booms are positioned within the lower slots and the booms may be slid into the upper slots or the structures are raised / positioned such that theRef. No. <038191.01372>corresponding booms may be within the upper slots. The booms may be fastened or bonded to the lower slots before or after the structures are raised / positioned such that the corresponding booms are within the upper slots. In another example, the structures may be positioned or raised such that the booms are positioned within the upper slots and the booms may be slid into the lower slots or the structures are lowered / positioned such that the corresponding booms may be within the lower slots. The slots may be formed with a void within the side where the corresponding booms are able to be inserted / positioned / lowered / raised within the slots. The booms may be connected to and / or bonded to the structure. Thus, the structures of the forward tip structure are connected together and the structures of the rear tip structure are connected together. For example, an adhesive may be applied within the slots to bond the booms to the structures and / or a fastener or other joining device(s) may connect the booms to the structures. The booms may be fixed to a jig or held by one or more robots such the robot(s) slide / position the booms within the apertures / slots of the structures. Each of the structures may be formed / produced by 3D printing such as powder bed fusion or other types of manufacturing methods. The booms and structures may be made from a composite material or an alloy such as aluminum (Al) alloys or nickel (Ni) alloys.

[0192] Wing(s)

[0193] Each of the one or more propulsion wing frames / structures and the one or more wing frames / structures of each wing may include a plurality (e.g., two lower and two upper apertures / slots as shown in the below illustrations) of lower apertures / slots and upper apertures / slots formed within the frames / structures. The plurality of apertures / slots may be transverse to the axial direction (i.e., front to aft direction) of the main fuselage structure as shown in the below illustrations. The frames / structures, individually or in combination, may be lowered / positioned and / or raised / positioned such that the corresponding booms are slid / positioned within apertures / slots. In one example, the frames may be positioned such that the booms may be slid into each of the apertures / slots. In another example, the frames may be lower / positioned such that the booms are positioned within the lower slots and the booms may be slid into the upper slots or the frames are raised / positioned such that the corresponding booms may beRef. No. <038191.01372>within the upper slots. The booms may be fastened or bonded to the lower slots before or after the frames are raised / positioned such that the corresponding booms are within the upper slots. In another example, the frames may be positioned or raised such that the booms are positioned within the upper slots and the booms may be slid into the lower slots or the frames are lowered / positioned such that the corresponding booms may be within the lower slots. The slots may be formed with a void within the side where the corresponding booms are able to be inserted / positioned / lowered / raised within the apertures / slots. The booms may be connected to and / or bonded to the frames. For example, an adhesive may be applied within the slots to bond the booms to the frames and / or a fastener or other joining device(s) may connect the booms to the frames. The booms may be fixed to a jig or held by one or more robots such the robot(s) slide / position the booms within the slots of the frames. Each of the frames of each wings may be formed / produced by 3D printing such as powder bed fusion or other types of manufacturing methods. The booms may be made from a composite material or an alloy such as aluminum (Al) alloys or nickel (Ni) alloys.

[0194] Tail(s)

[0195] The tails(s) may be connected to the intermediate structure and / or the rear tip structure by pins in lugs of the intermediate structure and / or the rear tip structure and also with power and information / data connectors.

[0196] Skin(s)

[0197] One or more skins may be adhesively bonded or fastened via fasteners or other fastening devices to the core fuselage structure. The skin may be shrink fit over the core fuselage structure forming at least part of the connection to the core fuselage structure. The skins may be made from alloys, composite materials or plastics. The skin may be formed / produced by 3D printing such as powder bed fusion or other types of manufacturing methods.

[0198] In any of the disclosure and embodiments, coupling and coupler may include mechanical, electrical, chemical or a combination thereof. For example, mechanical fasteners, electrical coupling and adhesives may include coupling or couplers.

[0199] The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to theseRef. No. <038191.01372>example embodiments presented throughout this disclosure will be readily apparent to those skilled in the art. and the concepts disclosed herein may be applied to other techniques of forming and assembling the disclosed example embodiments. Thus, the claims are not intended to be limited to the exemplary embodiments presented throughout the disclosure, but are to be accorded the full scope consistent with the language of the claims. All structural and functional equivalents to the elements of the exemplary embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. §112(f), or analogous law' in applicable jurisdictions, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”

Claims

Ref. No. <038191.01372>CLAIMS WHAT IS CLAIMED IS:

1. An aircraft wing structure, comprising:a wing box substructure comprising one or more structures, wherein each of the one or more structures comprises two spar webs, rib portions connecting the two spar webs, and a plurality of attachment features; andfour composite spar caps fixed to the plurality of attachment features.

2. The aircraft wing structure of claim 1, wherein the four composite spar caps are fixed to the plurality of attachment features with an adhesive.

3. The aircraft wing structure of claim 2, wherein each of the plurality of attachment features comprises an opening, and wherein each of the openings is configured to contain one of the four composite spar caps.

4. The aircraft wing structure of claim 1, wherein the four composite spar caps comprise carbon fibers.

5. The aircraft wing structure of claim 4, wherein the four composite spar caps further comprises a resin, and wherein the carbon fibers are combined with the resin.

6. The aircraft wing structure of claim 4, further comprising:a cover, wherein the carbon fibers comprise unidirectional carbon fibers within the cover, and wherein the cover is configured to prevent the carbon fibers from buckling under axial compression.

7. The aircraft wing structure of claim 6, wherein the cover comprises a plurality of apertures.

8. The aircraft wing structure of claim 6, wherein the cover comprises a coating configured to prevent galvanic corrosion between the cover and the carbon fibers.Ref. No. <038191.01372>9. The aircraft wing structure of claim 6, wherein the cover comprises a metal.

10. The aircraft wing structure of claim 1, wherein the wing box substructure comprises a plurality of the structures, and wherein the four composite spar caps connect the plurality of structures together.

11. The aircraft wing structure of claim 10, further comprising:a propulsor coupled to the wing box substructure.

12. The aircraft wing structure of claim 10, wherein two of the attachment features of one of the structures are fixed to one of the spar caps, and the two attachment features are separated by a gap.

13. The aircraft wing structure of claim 10, wherein one of the attachment features of a first structure of the plurality of structures spans one of the two spar webs of the first structure.

14. The aircraft wing structure of claim 1, wherein at least one of the structures is a unitary structure.

15. The aircraft wing structure of claim 14, wherein the unitary structure is a three dimensionally printed metal structure.

16. The aircraft wing structure of claim 10, wherein the plurality of structures spans the aircraft wing structure.

17. The aircraft wing structure of claim 16, further comprising a skin coupled to the rib portions of one or more of the plurality of structures.

18. The aircraft wing structure of claim 10, further comprising:Ref. No. <038191.01372>a fixing feature coupling a first portion of a first structure of the plurality of structures to a second portion of a second structure of the plurality of structures.

19. The aircraft wing structure of claim 18, wherein the fixing feature comprises a protrusion coupled to the first portion, and a recess coupled to the second portion, and wherein the protrusion is connected to the recess with an adhesive.

20. An aircraft architecture, comprising:a core system; anda plurality' of substitutable systems configured to be interchangeably coupled to the core system, the plurality’ of substitutable systems comprises a container system and a propulsion system, and wherein the container system is configured to transfer energy and electrical signals to the propulsion system.

21. The aircraft system of claim 20, wherein the plurality of substitutable systems further comprises a tail system configured to be coupled to the core system.

22. The aircraft system of claim 20, wherein the container system comprises a power source generating energy, such that the generated energy is supplied to the propulsion system.

23. The aircraft system of claim 20, wherein the propulsion system comprises one or more propulsors.

24. The aircraft system of claim 20, wherein the container system comprises a plurality of containers configured to be coupled together.

25. The aircraft system of claim 20, wherein the plurality' of substitutable systems further comprises a wing system configured to be coupled to the core system.

26. The aircraft system of claim 25, wherein the propulsion system is coupled to the wing system.Ref. No. <038191.01372>27. The aircraft system of claim 20, wherein the core system comprises a plurality of structures, wherein the plurality of structural comprises a plurality of unitary structures coupled together, and wherein the wing system is connected to and removeable from one or more of the unitary structures.

28. The aircraft system of claim 27, wherein the wing system comprises two wings, wherein a first wing is connected to and removeable from a first unitary structure of the plurality of unitary structures and a second wing is connected to and removeable from a second unitary structure of the plurality' of unitary' structures.

29. The aircraft system of claim 27. further comprising a plurality of composite booms, and wherein the plurality' of structures are coupled together with the plurality of composite booms.

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