Additively Manufactured Suppressor With Integral Baffles
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Solution Overview
Problem
Existing suppressor manufacturing techniques face challenges such as inaccurate baffle positioning, time-consuming and costly assembly processes, potential baffle strike hazards, and weight issues due to redundant materials, as well as difficulties in using additive layer manufacturing methods like selective metal melting (SMM) for creating complex products with internal structures.
Innovation Solution
The use of selective metal melting techniques, specifically laser metal sintering (LMS), to manufacture suppressors with components formed integrally to the housing, where baffles are constructed at specific angles to optimize support and reduce heat stress, allowing for efficient and durable suppressor production without subsequent assembly, and the integration of a quick connect system for secure attachment to gun barrels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing techniques (deforming rigid sheet material or machining) are used to construct suppressors, then the suppressor can be manufactured with conventional methods, but the manufacturing process is time-consuming and costly
Solution Approach 1:
The patent applies selective metal melting (SMM) technology to manufacture suppressors, fundamentally changing the manufacturing parameter from conventional deformation or machining methods to additive layer manufacturing. This enables complex internal baffle structures to be manufactured directly from digital models, significantly reducing manufacturing time and cost while improving productivity
Solution Approach 2:
The patent replaces traditional mechanical manufacturing methods (deforming rigid sheet material, machining, welding, fastening) with a thermal-based additive manufacturing process. The SMM technology uses selective melting of metal powder layers to build suppressor components, eliminating the need for mechanical assembly operations and improving manufacturing efficiency
2Ease of manufacture
If baffles are manufactured separately and secured to the suppressor body using welding or fasteners, then the suppressor can be assembled using conventional techniques, but inaccurate baffle positioning and potential baffle strike hazards occur
Solution Approach 1:
The patent merges the baffle and suppressor body into a single integrated component manufactured using SMM technology. The baffle is formed as an integral part of the suppressor housing, eliminating separate assembly operations and ensuring precise positioning without the risk of baffle strike. This integration resolves the contradiction between ease of manufacture and positioning accuracy
Solution Approach 2:
The SMM manufacturing process performs the positioning action preliminarily during the building process itself. As each layer is deposited and melted, the baffle structure is automatically positioned with high precision relative to the suppressor body, eliminating the need for subsequent assembly and positioning adjustments
3Ease of manufacture
If conventional manufacturing methods are used with separate components, then the suppressor can be assembled using standard techniques, but redundant materials increase the suppressor weight
Solution Approach 1:
The patent combines multiple separate components (suppressor body, baffles, and internal structures) into a single integrated SMM-manufactured component. This eliminates redundant materials that would be present in conventional assembly methods (such as fasteners, weld material, and spacing elements), thereby reducing the overall suppressor weight while maintaining structural integrity
Solution Approach 2:
The SMM technology enables local deposition of material only where required for structural support or functional performance. This creates an optimized material distribution within the suppressor, eliminating unnecessary material in non-critical areas and reducing overall weight compared to conventional manufacturing methods that require uniform wall thicknesses and additional fastening components
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 enhances the accuracy and efficiency of suppressor manufacturing, reduces the risk of baffle strike, and results in a lighter, more effective noise-reducing device with improved durability and ease of use, while enabling the combination of a muzzle brake and quick connect system within a reflex-style suppressor design.
Implementation Method 1
melting the feed material to form part of the housing
Implementation Method 2
the method uses a selective metal melting technique
Data Source
AI summary
A suppressor having a body and a first connector half coupled to the body, wherein the first connector half includes a first component that includes at least one channel and a first surface; and wherein the body provides a second surface, wherein a gap between the first surface and the second surface defines at least one track; wherein the gun includes a second connector half comprising at least one protrusion, wherein the protrusion and channel have corresponding shapes that allow the protrusion to be inserted through the channel and into alignment with the track, wherein the first component may be rotated with respect to the protrusion and the body to bring the protrusion out of alignment with the channel so that the first and second surfaces clamp the protrusion to thereby secure the first connector half and second connector half with respect to each other.