Additive Manufacturing Device for Aerospace Truss Formation
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Solution Overview
Problem
Current methods for manufacturing composite trusses, especially for aerospace applications, are cumbersome, inefficient, and result in inconsistent products due to the lack of mature additive manufacturing devices, leading to long processing cycles and poor product consistency.
Innovation Solution
An additive manufacturing device specifically designed for aerospace trusses, comprising a raw material input unit, longitudinal beam forming unit, longitudinal beam traction unit, and truss support unit, which enables rapid in-situ formation of composite trusses by sequentially forming and shaping longitudinal and cross beams using pre-impregnated tapes and wires, with temperature control and precise mechanical mechanisms for efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional machining and bonding methods are used to manufacture composite trusses, then the manufacturing process can be completed with existing equipment, but the process becomes cumbersome and the processing cycle is long
Solution Approach 1:
The patent changes the manufacturing parameters from traditional machining and bonding to additive manufacturing with in-situ forming. The composite truss is formed directly through layered deposition and curing processes, transforming the manufacturing approach from subtractive and assembly-based to additive and in-situ formation, thereby dramatically reducing processing cycles and process complexity
Solution Approach 2:
The patent replaces traditional mechanical machining and bonding systems with an additive manufacturing system that uses controlled material deposition and in-situ curing. The mechanical assembly process is substituted by a automated layer-by-layer construction process, reducing both manual intervention and process complexity
2Manufacturing precision
If manual preparation is used for layering truss structures, then the process can be performed with simple equipment, but the processing cycle is long and product consistency is poor
Solution Approach 1:
The patent implements self-service through automated material feeding systems and in-situ curing mechanisms. The system automatically feeds pre-impregnated tapes and wires, controls layer deposition, and applies curing heat without manual intervention, ensuring consistent quality while accelerating production
Solution Approach 2:
The patent achieves continuous manufacturing through uninterrupted layer-by-layer deposition and in-situ curing processes. The additive manufacturing system operates continuously without the stop-start nature of manual preparation, maintaining consistent material properties and structural quality throughout the entire truss fabrication process
3Productivity
If additive manufacturing technologies are used for forming trusses, then rapid in-situ formation can be achieved, but the devices are not yet mature and no specific device exists for aerospace trusses
Solution Approach 1:
The patent segments the additive manufacturing device into specialized functional modules: raw material input unit, longitudinal beam forming unit, cross beam forming unit, and control system. This modular segmentation allows each component to be optimized for aerospace truss manufacturing while maintaining overall system reliability through proven subsystem architectures
Solution Approach 2:
The patent creates a universal additive manufacturing device capable of producing various aerospace truss configurations through programmable control. The system can adapt to different truss designs, dimensions, and material requirements while maintaining consistent manufacturing quality, establishing device maturity through versatile application capability
4Manufacturing precision
If layered truss structures are formed manually, then the process can be performed with basic equipment, but resin and fiber statuses inside trusses are inconsistent
Solution Approach 1:
The patent replaces manual material handling with automated precision feeding systems that control the deposition of pre-impregnated tapes and wires. The system ensures consistent resin-to-fiber ratios and uniform material distribution through automated dosing and placement mechanisms, eliminating the variability inherent in manual preparation
Solution Approach 2:
The patent implements feedback control through sensors and monitoring systems that track material deposition, layer formation, and curing progress. This closed-loop control ensures consistent material status throughout the truss structure by detecting and correcting deviations in real-time, maintaining uniform resin and fiber properties without requiring overly complex manufacturing systems
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 device achieves rapid and efficient formation of composite trusses with improved stability and consistency, addressing the inefficiencies and inconsistencies of existing methods by enabling high-speed, in-situ manufacturing of aerospace trusses.
Implementation Method 1
the pre-impregnated tapes passing through the molds form the required longitudinal beams by controlling the temperature of the molds
Data Source
AI summary
An additive manufacturing device for an aerospace truss includes a raw material input unit, a longitudinal beam forming unit, a longitudinal beam traction unit, a cross beam forming unit and a truss support unit. The raw material input unit stores pre-impregnated wires and pre-impregnated tapes, and a motor drives rollers to convey the pre-impregnated wires and the pre-impregnated tapes forward; the longitudinal beam forming unit is composed of three sets of forming molds, and the pre-impregnated tapes form V-shaped longitudinal beams through heating molds; a stepper motor used in the longitudinal beam traction unit drives three sets of roller traction devices through steering gears to pull formed longitudinal beams; the cross beam forming unit is composed of a motion module and a printing module, and a truss cross beam is printed through a 3D printing method of molten deposition.