Tri-axially Optimized AM Core Panels for Multi-directional Load Support
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Solution Overview
Problem
Traditional honeycomb and lattice manufacturing processes for transport structures are labor and tooling intensive, resulting in anisotropic properties that cannot effectively support loads from multiple directions, leading to increased manufacturing costs, complexity, and compromised performance due to directional limitations and material gradients.
Innovation Solution
The use of additive manufacturing (AM) to create tri-axially optimized cores with varying strength across the panel, allowing for customized support of expected load conditions by optimizing the core structure in all three dimensions and integrating it with face sheets using techniques like Direct Metal Deposition and Powder Bed Fusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional honeycomb manufacturing processes are used, then the core provides stiffness in one direction, but the panel cannot support loads from multiple directions due to anisotropic properties
Solution Approach 1:
The patent applies local quality by varying the density and structural characteristics of the core material at different locations throughout the panel. The core transitions from uniform traditional honeycomb structures to gradient structures where material properties change continuously across the panel, allowing different regions to optimize for different load directions and magnitudes.
Solution Approach 2:
The patent employs composite materials by combining the core structure with face sheets to create a sandwich panel system. The core itself uses composite material distributions with varying densities and structural configurations to achieve multi-directional load support while maintaining lightweight properties.
2Adaptability or versatility
If composite core with distinct layers is produced to target different load aspects, then directional characteristics are improved, but manufacturing costs and complexity increase
Solution Approach 1:
The patent merges multiple manufacturing operations into a single additive manufacturing process. Instead of separately manufacturing different core layers and then assembling them, the gradient core structure is built continuously in one process, eliminating the need for multiple tooling sets and assembly steps while achieving the same directional load support characteristics.
Solution Approach 2:
The patent utilizes parameter changes by systematically varying material density, pore size, and structural geometry parameters throughout the core during the additive manufacturing process. These continuous parameter variations allow optimization for different load directions without requiring discrete layer changes or multiple manufacturing processes.
3Ease of manufacture
If traditional honeycomb structures are used, then manufacturing is labor and tooling intensive, but additive manufacturing requires specialized equipment and process optimization
Solution Approach 1:
The patent replaces traditional mechanical manufacturing systems (cutting, molding, assembling) with additive manufacturing technology. This substitution eliminates the need for dedicated tooling and labor-intensive assembly operations, though it introduces specialized AM equipment and process control requirements.
Solution Approach 2:
The additive manufacturing process inherently performs multiple functions that would otherwise require separate operations. The single build process simultaneously creates the core structure, integrates material property gradients, and eliminates the need for post-assembly operations, making the system self-sufficient despite the specialized equipment required.
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 panels with quasi-isotropic properties, improved load distribution, reduced mass, and enhanced performance by integrating optimized core structures with face sheets, addressing the limitations of traditional methods while reducing manufacturing complexity and costs.
Implementation Method 1
integrating it with face sheets using techniques like Direct Metal Deposition and Powder Bed Fusion
Implementation Method 2
integrating it with face sheets using techniques like Direct Metal Deposition and Powder Bed Fusion
Data Source
AI summary
The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component.