Patent ID: 11897074
Assignee: THE BOEING COMPANY
Field: Machine tools (Mechanical engineering)
Classification: CPC B | IPC B

Claim 7:
8. A method of making a needle array for forming ultrasonic perforations, the method comprising:
additively manufacturing a plurality of needles via 3D printing, wherein the plurality of needles is arranged to form the needle array according to claim 1, wherein each respective needle of the plurality of needles extends longitudinally from a respective first end to a respective second end forming a tip, wherein the plurality of needles is configured to repeatedly contact the workpiece at the ultrasonic operating frequency such that each respective needle of the needle array forms the respective hole through the workpiece; and
additively manufacturing the support plate configured to secure a respective position of each respective needle with respect to each other needle of the plurality of needles such that the plurality of needles defines the needle array, wherein the first ends of the plurality of needles are integrally formed with the support plate, wherein the plurality of needles extend away from the support plate such that the tips of the plurality of needles are spaced apart from the support plate, and wherein the support plate is integrally formed with the plurality of needles.