Modular Payload Dispenser Using Additive Manufacturing

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Solution Overview

Problem

Existing weapon systems lack a lightweight, modular, and efficient payload dispenser capable of distributing munitions in a toroidal radius from aerial vehicles.

Innovation Solution

A modular payload dispenser system utilizing additive manufacturing and mechanical energy storage, featuring a munitions dispenser with flicker assemblies arranged in a circular pattern, powered by springs and controlled by a servo motor and sear latch assembly for sequential or simultaneous munition release.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If traditional manufacturing methods are used for payload dispensers, then structural strength and durability are improved, but weight increases and manufacturing complexity increases

Engineering Contradiction:

Improvepayload dispenser weightVSAvoidstructural strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent changes the manufacturing parameters and methods by using additive manufacturing (3D printing) instead of traditional subtractive or formative manufacturing. This allows for optimized lattice structures and topology that reduce weight while maintaining strength through carefully designed material distribution at the component level.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material structures, particularly in the form of lattice infill patterns combined with solid outer shells, creating a hierarchical composite structure that provides high strength-to-weight ratio. The additive manufacturing process enables integration of different materials and densities within single components.

Inventive Principle:

Principle #40Composite materials

2Duration of action of moving object

If mechanical energy storage systems are added to the payload dispenser, then operational duration and reliability are improved, but device complexity increases

Engineering Contradiction:

Improveoperational durationVSAvoidsystem complexity

Core Design Contradiction:

Duration of action of moving objectVSDevice complexity

Solution Approach 1:

The spring-loaded mechanism is designed to be self-contained and self-actuating. The mechanical energy storage system automatically converts stored potential energy into kinetic energy to drive the ejection sequence, requiring no external power source or complex control systems during operation. The system serves itself by using the payload's own mass and the spring's stored energy to complete the ejection function.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces electronic or powered ejection systems with a purely mechanical spring-loaded mechanism. This substitution eliminates the need for motors, batteries, or complex control electronics, reducing system complexity while maintaining reliable operation through proven mechanical energy storage and release principles.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If additive manufacturing is used for payload dispenser components, then weight is reduced and manufacturing efficiency is improved, but manufacturing precision challenges increase

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidcomponent precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The payload dispenser is divided into multiple separately manufactured components that are later assembled. This segmentation allows each component to be optimized for additive manufacturing processes, with tolerances and features designed specifically for 3D printing. Critical precision features are concentrated in fewer components, making quality control more manageable.

Inventive Principle:

Principle #1Segmentation

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 system effectively disperses munitions in a toroidal pattern with high precision and efficiency, leveraging lightweight construction and energy storage for extended operational capability.

Implementation Method 1

The system is designed to be lightweight, primarily constructed using additive manufacturing, and include a mechanical method of energy storage, such as a spring, such that potential energy may be stored for long periods of time.

Methodology Applied

Scientific EffectSpring: Spring

Implementation Method 2

The latch includes a bipolar magnetic latch comprising a first and second magnet pair, such that the first magnetic pair is arranged to magnetically repel each other and the second magnetic pair is arranged to magnetically attract each other.

Methodology Applied

Scientific EffectMagnetic repulsion: Ion Repulsion/Attraction

Implementation Method 3

Methodology Applied

Scientific EffectMagnetic attraction: Ion Repulsion/Attraction

Implementation Method 4

the munitions dispenser includes a servo motor, a plurality of sear latches, a pawl, such that the servo motor moves the plurality of sear latches to release the pawl such that the doors of each flicker assembly to be opened sequentially

Methodology Applied

Scientific EffectServo motor: Linear Motor

Data Source

PatentUS20250171145A1Lightweight Modular Payload Dispenser

Publication Date: 2025.05.29 USA AS REPRESENTED BY THE SECRETARY OF THE NAVY

AI summary

An apparatus that includes a munitions dispenser comprising a plurality of flicker assemblies. The flicker assemblies include a flicker arm and a guide wall arranged in a circular pattern.