Additive Manufacturing Acoustic Panels Intersecting Slats
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Solution Overview
Problem
Current methods for manufacturing acoustic panels are labor-intensive and costly due to the need for meticulous assembly of cells and insertion of septa, which is undesirable for aircraft applications where noise reduction is critical.
Innovation Solution
A system and method for generating computational models of three-dimensional structures with intersecting slats to create large-scale apertures, allowing for additive manufacturing of substrates without manual perforation or septum insertion, using a computing device to output instructions for an additive manufacturing apparatus to produce substrates with specific aperture configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If acoustic panels are assembled cell by cell with manual insertion of septa, then the panels can conform to complex geometries and provide effective noise reduction, but the manufacturing process becomes labor-intensive and costly
Solution Approach 1:
The acoustic panel is divided into modular units with standardized aperture patterns that can be manufactured separately and then assembled. The complex geometry is broken down into repeating geometric patterns of slats and apertures that can be produced efficiently using additive manufacturing, reducing manual labor while maintaining acoustic performance.
Solution Approach 2:
The patent transitions from two-dimensional aperture patterns to three-dimensional structures with slats having varying heights and orientations. This adds a vertical dimension to the aperture design, enabling complex acoustic functionality to be integrated into the structural elements themselves, thereby simplifying the overall manufacturing process while maintaining noise reduction effectiveness.
2Manufacturing precision
If traditional manufacturing methods are used with manual assembly, then precise control over aperture geometry can be achieved, but production time and costs increase significantly
Solution Approach 1:
The aperture patterns and slat configurations are pre-designed using computational modeling and optimization algorithms before manufacturing. This preliminary digital prototyping and geometric optimization allows for precise aperture geometry to be achieved through automated additive manufacturing processes, eliminating the need for manual adjustment while maintaining high production speed.
Solution Approach 2:
The patent replaces manual mechanical assembly operations with automated additive manufacturing processes. The complex aperture geometries that previously required meticulous hand assembly are now produced directly through digital fabrication, achieving both high precision and rapid production simultaneously.
3Reliability
If numerous septa are inserted into each cell, then acoustic control can be optimized, but the manufacturing expense and process complexity increase
Solution Approach 1:
The patent merges the functions of multiple septa into integrated slat structures. Instead of inserting numerous separate septa into each cell, the slats themselves are designed with varying heights, orientations, and configurations that provide the same acoustic control functionality. This consolidation reduces assembly complexity while maintaining acoustic performance.
Solution Approach 2:
The slat structures serve multiple functions simultaneously: they define aperture geometries, provide acoustic control, and form the structural framework of the panel. This multi-functionality eliminates the need for separate septa components and their associated complex insertion processes, achieving acoustic control optimization through a simplified unified structure.
Data Source
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AI summary
In an example, systems and methods for modeling apertures for additive manufacturing is disclosed. In an example, a computing device includes a processor configured to carry out operations. The operations include generating a computational model of a three-dimensional structure. The three-dimensional structure includes a first group of slats including a first plurality of slats substantially parallel to each other along a first axis and a second group of slats comprising a second plurality of slats substantially parallel to each other along a second axis, wherein the second group of slats intersects the first group of slats. The operations include outputting instructions for manufacturing a substrate in accordance with the generated computation model of the three-dimensional structure. The system includes an additive manufacturing apparatus communicatively coupled to the computing device and configured to receive the instructions and manufacture the substrate in accordance with the generated computation model of the three-dimensional structure.