Additive Rotor Blade Lattice Structure for Faster Manufacturing
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Solution Overview
Problem
Conventional aircraft rotor blade manufacturing is time-consuming and costly due to the need for multiple detail parts and sub-assemblies, which complicates the integration of structural load paths and increases expenses, especially when dealing with polymeric and metallic materials that undergo changes in pressure and temperature.
Innovation Solution
The use of additive manufacturing processes such as electron beam melting, selective laser sintering, and stereolithography to design and form a single-piece rotor blade with a tailored support network, upper skin, and lower skin, allowing for customized internal and external structures to enhance structural efficiency and reduce manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-step manufacturing process with separate detail parts is used, then control over manufacturing process and meeting operational requirements is improved, but manufacturing time and complexity increase
Solution Approach 1:
The patent merges multiple separate detail parts and sub-assemblies into a single integrated rotor blade structure manufactured through additive manufacturing. This consolidation eliminates the need for separate fabrication and assembly steps while maintaining structural integrity and operational performance through the digitally controlled layer-by-layer construction process.
Solution Approach 2:
The patent utilizes additive manufacturing technology to fundamentally change the manufacturing parameters from conventional subtractive or assembly-based methods. This enables direct digital manufacturing of complex geometries with precise control over material deposition, layer thickness, and structural properties, reducing manufacturing time while ensuring operational requirements are met.
2Strength
If separate spar members and sub-assemblies are used, then structural integrity can be ensured, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent integrates the spar member function directly into the unified rotor blade structure created through additive manufacturing. The support network and structural elements are built as an integrated lattice framework within the single piece, eliminating separate spar components and their associated assembly processes while maintaining load-bearing capacity.
Solution Approach 2:
The patent applies local quality by varying the density and configuration of the internal support network at different locations within the rotor blade. The additive manufacturing process enables region-specific optimization of material distribution, providing enhanced structural integrity where loads are highest while reducing material usage in lower-stress areas.
3Manufacturing precision
If conventional manufacturing tools and assembly processes are used, then precise assembly can be achieved, but manufacturing cost and shop floor space requirements increase
Solution Approach 1:
The patent eliminates the need for multiple separate manufacturing tools and assembly operations by consolidating the entire rotor blade production into a single additive manufacturing process. This digital fabrication approach replaces conventional tooling and assembly fixtures, reducing manufacturing costs and shop floor space requirements while maintaining precision through software-controlled layer deposition.
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
This approach enables the production of rotor blades with improved structural efficiency and reduced manufacturing costs by allowing for the creation of complex geometries and tailored properties directly, eliminating the need for separate spar members and reducing the reliance on expensive tools and large shop floor space.
Implementation Method 1
The additive manufacturing process can include at least one of the following: electron beam melting, selective laser sintering, selective laser melting (SLM), stereolithography, direct metal laser sintering, three-dimensional printing, fused deposition modeling, laser curing and lasered engineered net shaping.
Implementation Method 2
The additive manufacturing process can include at least one of the following: electron beam melting, selective laser sintering, selective laser melting (SLM), stereolithography, direct metal laser sintering, three-dimensional printing, fused deposition modeling, laser curing and lasered engineered net shaping.
Implementation Method 3
The additive manufacturing process can include at least one of the following: electron beam melting, selective laser sintering, selective laser melting (SLM), stereolithography, direct metal laser sintering, three-dimensional printing, fused deposition modeling, laser curing and lasered engineered net shaping.
Implementation Method 4
The additive manufacturing process can include at least one of the following: electron beam melting, selective laser sintering, selective laser melting (SLM), stereolithography, direct metal laser sintering, three-dimensional printing, fused deposition modeling, laser curing and lasered engineered net shaping.
Implementation Method 5
The additive manufacturing process can include at least one of the following: electron beam melting, selective laser sintering, selective laser melting (SLM), stereolithography, direct metal laser sintering, three-dimensional printing, fused deposition modeling, laser curing and lasered engineered net shaping.
Implementation Method 6
The additive manufacturing process can include at least one of the following: electron beam melting, selective laser sintering, selective laser melting (SLM), stereolithography, direct metal laser sintering, three-dimensional printing, fused deposition modeling, laser curing and lasered engineered net shaping.
Implementation Method 7
The additive manufacturing process can include at least one of the following: electron beam melting, selective laser sintering, selective laser melting (SLM), stereolithography, direct metal laser sintering, three-dimensional printing, fused deposition modeling, laser curing and lasered engineered net shaping.
Data Source
AI summary
An airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member including an upper skin; a lower skin; and a support network having a plurality of interconnected support members in a lattice arrangement and/or a reticulated arrangement, the support network being configured to provide tailored characteristics of the airfoil member. Also provided are methods and systems for repairing an airfoil member.