3D-Printed Reticulated Foam Inserts for Fuel Tank Fit

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Solution Overview

Problem

Existing methods for manufacturing foam inserts for fuel tanks are laborious and costly due to the need for subtractive manufacturing to shape quenched foam buns, which do not efficiently accommodate the structural features of fuel tanks, increasing the risk of fuel vapor ignition from electrical arcing.

Innovation Solution

Utilize additive manufacturing to create foam inserts that account for fuel tank structures by depositing polyurethane in specific shapes, followed by quenching to form reticulated foam, or forming lattice patterns without additional processing, thereby reducing labor and tooling requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If subtractive manufacturing is used to shape quenched foam buns, then foam inserts can be produced, but the process becomes laborious and costly with increased tooling requirements

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidproduction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent inverts the conventional manufacturing sequence by using additive manufacturing to create foam inserts directly in their final shape, eliminating the need for subtractive manufacturing of quenched foam buns. This reversal of the process sequence resolves the contradiction by making the manufacturing process simpler while simultaneously improving productivity through direct fabrication.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent replaces mechanical subtractive manufacturing processes with additive manufacturing technology. This substitution eliminates labor-intensive cutting and shaping operations, reducing both manual labor requirements and tooling needs while maintaining production efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional foam inserts are used, then manufacturing is simpler, but they do not efficiently accommodate fuel tank structural features, increasing ignition risk

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidfuel vapor ignition prevention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies local quality by creating foam inserts with spatially varying properties that specifically accommodate local structural features of the fuel tank. The additive manufacturing process enables customization of foam density, shape, and configuration at different locations to match local tank geometry and structural requirements, thereby improving ignition prevention while maintaining manufacturing feasibility.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent utilizes parameter changes by varying foam insert characteristics (density, porosity, shape) based on specific fuel tank structural features. The additive manufacturing process allows precise control of these parameters to optimize vapor accumulation prevention in different regions of the fuel tank, enhancing reliability without sacrificing manufacturing ease.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If foam inserts are manufactured using traditional methods, then production can proceed, but labor and tooling costs increase

Engineering Contradiction:

Improveproduction outputVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent replaces complex mechanical subtractive manufacturing systems with additive manufacturing technology. This substitution maintains high production output by enabling direct fabrication of foam inserts without requiring multiple processing steps, tooling changes, or manual intervention, thereby simplifying the manufacturing process while preserving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The additive manufacturing process reduces labor and costs associated with shaping foam inserts, ensuring they fit seamlessly into fuel tanks, minimizing fuel vapor accumulation and ignition risks.

Implementation Method 1

forming, via additive manufacturing, a foam insert having a shape based on one or more properties of a fuel tank

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Implementation Method 2

quenching the foam insert to form a reticulated foam insert

Methodology Applied

Scientific EffectQuenching: Reticulated Foam

Data Source

PatentUS20250345996A1Systems, apparatus, and methods for manufacturing foam inserts for fuel tanks

Publication Date: 2025.11.13 THE BOEING CO

AI summary

Systems, apparatus, and methods for manufacturing foam inserts for fuel tanks are disclosed. An example method includes forming, via additive manufacturing, a foam insert having a shape based on one or more properties of a fuel tank that is to receive the foam insert; and quenching the foam insert to form a reticulated foam insert.