Additive Rotor Blade Lattice Structure for Dynamic Load Resistance
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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 with polymeric and metallic materials experiencing variations in pressure and temperature.
Innovation Solution
The use of additive manufacturing processes such as electron beam melting, selective laser sintering, and stereolithography to create a tailored rotor blade with a support network that includes closely compacted and open cell portions, allowing for a one-piece airfoil member with varying thickness and density, eliminating the need for a conventional spar by distributing loads across the upper and lower skins.
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 cost increase significantly
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 fabrication of complex three-dimensional structures with precise control over material deposition, layer thickness, and structural properties, dramatically reducing manufacturing time while ensuring operational requirements are met.
2Ease of manufacture
If conventional multi-step manufacturing process with separate detail parts is used, then control over manufacturing process is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent combines multiple manufacturing operations and separate component fabrication into a single additive manufacturing process. This integration eliminates the need for multiple specialized tooling sets and assembly operations, reducing overall manufacturing cost while maintaining digital control over the entire production process through software-driven layer-by-layer construction.
Solution Approach 2:
The patent changes the fundamental manufacturing approach from conventional multi-step processes to additive manufacturing, altering parameters such as material utilization, production time, and tooling requirements. This enables direct digital fabrication that reduces waste and eliminates expensive tooling while maintaining precise control through digital modeling and process parameters.
3Productivity
If additive manufacturing is used to create one-piece airfoil member, then manufacturing time and cost are reduced, but structural integrity under dynamic loads must be maintained
Solution Approach 1:
The patent applies local quality by varying the density and structural characteristics of different regions within the rotor blade. The support network structure incorporates varying cell densities and material distributions tailored to specific load zones, ensuring optimal structural integrity in high-stress areas while maintaining manufacturing efficiency through the additive process.
Solution Approach 2:
The patent utilizes composite material structures within the additive manufacturing process, combining different materials or material densities within the single airfoil member. The support network incorporates varying material properties to withstand dynamic loads while maintaining the benefits of additive manufacturing, such as reduced production time and cost.
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 reduces manufacturing costs and time, enhances structural efficiency, and allows for the production of rotor blades with tailored internal and external structures in a single operation, improving the rotor blade's ability to withstand dynamic loads while maintaining a smooth exterior surface.
Implementation Method 1
additive manufacturing processes such as electron beam melting
Implementation Method 2
selective laser sintering
Implementation Method 3
selective laser melting (SLM)
Implementation Method 4
stereolithography
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
In a first aspect, there is a method of making a rotor blade (101), including designing at least one of an upper skin (119), a lower skin (121), a support network (123), and components therefor; and forming at least one of the upper skin (119), the lower skin (121), a support network (123), and components therefor using an additive manufacturing process. In a second aspect, there is an airfoil member having a root end (103), a tip end (105), a leading edge (107), and a trailing edge (109), the airfoil member including an upper skin (119); a lower skin (121); and a support network (123) having a plurality of interconnected support members (123) in a lattice arrangement and/or a reticulated arrangement, the support network (123) being configured to provide tailored characteristics of the airfoil member. Also provided are methods and systems for repairing an airfoil member.