Additive-Manufactured Airframe Structure With Nested Reinforcement

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Solution Overview

Problem

Conventional additive manufacturing of structures results in either weak or heavy components unsuitable for desired applications, and existing materials like carbon fiber are expensive and limit easy development.

Innovation Solution

An additive manufactured airframe structure incorporating reinforcement elements received within hollow portions of airframe segments, providing shear, tensile, and compressive strength using materials like carbon fiber, fiberglass, and metal rods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional additive manufacturing is used to produce airframe structures, then manufacturing flexibility and rapid part change capability are improved, but the resulting structures are weak and heavy

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidstructural strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent combines additive manufactured airframe segments with traditional reinforcement elements (such as carbon fiber, fiberglass, or metal rods) to create a composite structure. The reinforcement elements are received within hollow portions of the additive manufactured segments, creating a hybrid structure that leverages the manufacturing flexibility of additive technology while incorporating the proven strength characteristics of traditional composite reinforcement methods.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If conventional additive manufacturing is used to produce airframe structures, then manufacturing flexibility is improved, but the structures become heavy

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidairframe weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

By integrating high-strength reinforcement elements within the hollow portions of additive manufactured segments, the structure achieves the required mechanical strength with reduced material usage. The reinforcement elements provide structural integrity while the additive manufactured segments maintain design flexibility, resulting in a lighter overall structure compared to traditional fully-reinforced approaches.

Inventive Principle:

Principle #40Composite materials

3Strength

If traditional reinforcement materials like carbon fiber are used, then structural strength is improved, but material costs increase and development becomes less accessible

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing accessibility

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent allows for variation in reinforcement element materials (carbon fiber, fiberglass, metal rods) and configurations, enabling optimization based on cost, performance, and manufacturing capability. This flexibility in material selection and structural parameters makes the technology accessible to different development budgets and manufacturing capabilities while maintaining structural integrity.

Inventive Principle:

Principle #35Parameter changes

4Adaptability or versatility

If airframe structures are assembled from multiple components, then manufacturing flexibility and part replacement capability are improved, but mechanical properties are lost at assembly interfaces

Engineering Contradiction:

Improvepart replacement capabilityVSAvoidassembly interface strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The reinforcement elements are nested within hollow portions of the additive manufactured airframe segments, creating an integrated assembly where the reinforcement elements are received and secured within the segment geometry. This nesting approach ensures that the reinforcement elements and airframe segments work together as a unified structure, maintaining mechanical properties at the assembly interfaces while preserving the benefits of modular construction.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS20250313326A1Additive manufactured airframe structure having a plurality of reinforcement elements

Publication Date: 2025.10.09 RAPIDFLIGHT HOLDINGS LLC

AI summary

An additive manufactured airframe structure includes a first additive manufactured fuselage segment including a first outer wall that extends in a normal direction from a first end to a second end, and also includes a plurality of reinforcement elements extending from the second end of, and away from, the first outer wall in the normal direction. The airframe structure also includes a second additive manufactured fuselage segment formed separately from the first additive manufactured fuselage segment and including a second outer wall that extends in the normal direction from a first end to a second end, and a plurality of receiving channels extending along the second outer wall. The plurality of reinforcement elements are received in the plurality of receiving channels and link together the first and second additive manufactured fuselage segments.