3D Core Geometry Design for Compound-Curvature Composite Parts
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Solution Overview
Problem
Designing cores for composite parts with compound curvature characteristics is tedious and error-prone, leading to imprecise core construction that fails to effectively control the physical characteristics of the composite part.
Innovation Solution
A computing system with a 3D core design engine and printing engine that supports the digital design and additive manufacturing of 3D cores, allowing for precise definition of core characteristics such as curvature, shape, and internal composition based on the under-core ply and core design parameters, enabling accurate and efficient construction of additive 3D cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual design methods are used for cores with compound curvature, then the design process is simple to perform, but the manufacturing precision and fit accuracy deteriorate significantly
Solution Approach 1:
The patent uses digital copying of the under-core ply geometry from the composite part design to automatically generate the core's top surface geometry. This ensures the core precisely replicates the complex curvature characteristics of the composite part, achieving high fit accuracy without manual intervention. The digital model is copied and transformed through computational algorithms to define the core's three-dimensional shape.
Solution Approach 2:
The patent replaces manual mechanical design methods with automated computational design systems. Instead of physically measuring and drafting core geometries, the system uses computer algorithms to compute the core design from the composite part model, eliminating human error and achieving superior precision in complex curvature scenarios.
2Productivity
If traditional trial-and-error methods are used for core construction, then the manufacturing process is simple, but the productivity and design efficiency deteriorate
Solution Approach 1:
The patent performs preliminary computational design and analysis of the core geometry before manufacturing. The system calculates the optimal core shape, thickness distribution, and material properties in advance using the composite part model, allowing the actual manufacturing to proceed directly without trial-and-error adjustments, thereby improving both efficiency and reliability.
3Measurement precision
If manual core design is used, then the device complexity is low, but the measurement precision and control over physical characteristics deteriorate
Solution Approach 1:
The patent implements a feedback mechanism where the computed core design is validated against the composite part requirements. The system iteratively adjusts the core geometry based on feedback from structural analysis and fit checks, ensuring that the final design meets the precise curvature and physical characteristic requirements of the composite part.
Data Source
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AI summary
A system may include a 3D core design engine (110) and a 3D core printing engine (112). The 3D core design engine (110) may be configured to determine, in a CAD model (202), an under-core ply (210) of a composite part and a core footprint (220) on the under-core ply (210) specified for an additive 3D core to be manufactured via additive manufacturing for insertion into the composite part, compute a bottom core surface (230) of the additive 3D core from the under-core ply (210) and core footprint (220), access core design parameters for the additive 3D core; and construct an additive 3D core design (420) in the CAD model (202) based on the computed bottom core surface (230) and the core shape parameters (331, 332). The 3D core printing engine (112) may be configured to store the additive 3D core design (420) to support subsequent manufacture of the additive 3D core via additive manufacturing.