Systems and methods for co-casting of additively manufactured interface nodes

Systems and methods for co-casting of additively manufactured, high precision Interface Nodes are disclosed. The Interface Node includes an integrated structure including one or more complex or sophisticated features and functions. Co-casting of Interface Nodes by casting a part onto the Interface Node results in a hybrid structure comprising the cast part and the additively manufactured Interface Node. The interface node may include at least one of a node-to-tube connection, node-to-panel connection, or a node-to-extrusion connection. In an embodiment, engineered surfaces may be provided on the Interface Node to improve the blend between the Interface Node and the cast part during the co-casting process.

BACKGROUND

Field

The present disclosure relates generally to apparatus and techniques in manufacturing, and more specifically to co-casting of interface nodes for three-dimensional (3-D) printed components for use in producing vehicles, boats, aircraft and other mechanical structures.

Background

Three-dimensional (3-D) printing, which may also be referred to as additive manufacturing, is a process used to create 3-D objects. The 3-D objects may be formed using layers of material based on digital model data of the object. A 3-D printer may form the structure defined by the digital model data by printing the structure one layer at a time. 3-D printed objects may be almost any shape or geometry.

A 3-D printer may disseminate a powder layer (e.g., powdered metal) on an operating surface. The 3-D printer may then bond particular areas of the powder layer into a layer of the object, e.g., by using a laser to bond the powder of the powder layer together. The steps may be repeated to sequentially form each layer. Accordingly, the 3-D printed object may be built layer by layer to form the 3-D object.

3-D printing is non-design specific, which offers geometric and design flexibility that conventional manufacturing processes cannot. Furthermore, 3-D printing technologies can produce parts with very small feature sizes, and geometries that are either significantly difficult or impossible to produce using conventional manufacturing processes.

Very large components which exceed printer size specifications can be segregated at the design phase, printed in parallel and combined. The versatility of 3D printing, and its ability to create highly complex structures, is driving its increased adoption by the industry.

However, as the sophistication of the features of the 3-D printed part increases, the production volume would decrease. The production volume also decreases with the increasing size of the 3-D printed component. These practical limitations are often inherent in certain 3-D printing processes, which may rely on slower printing speeds for accurate rending of complex geometries.

Casting is a conventional manufacturing process that is well suited for high throughput production of voluminous or heavy structures. However, casting is not suitable for high-throughput production of more complex structures, which include structures with sophisticated internal features and other complex geometrical features. A significant amount of post-machining operations would be needed after the casting process, which would make the overall process prohibitively expensive for high-volume production of such complex structures relying solely on casting.

Techniques are consequently needed for integrating the benefits of AM and its ability to create complex structures with sophisticated features on one hand, with the advantages of casting, a higher-throughput manufacturing technique to effect decreased lead times and increased production capacities on the other hand, to thereby enable the manufacture of structures that enjoy the combined benefits of both.

3-D printed components may be used to produce sub-components for various devices or apparatus. The 3-D printed sub-components may need to be attached or connected to other sub-components, including other 3-D printed sub-components, extruded sub-components, or still other sub-components.

SUMMARY

Several aspects of apparatus for co-casting of interface nodes will be described more fully hereinafter with reference to three-dimensional printing techniques.

One aspect is an apparatus including an additively manufactured node. The apparatus also includes a cast part. The cast part may be cast onto the additively manufactured node. Accordingly, the apparatus may be a hybrid part. The hybrid part may include the additively manufactured node and the cast part.

It will be understood that other aspects of apparatus for co-casting of interface nodes will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only several embodiments by way of illustration. As will be realized by those skilled in the art, the apparatus for bridging are capable of other and different embodiments, and its several details are capable of modification in various other respects, all without departing from the invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appended drawings is intended to provide a description of various exemplary embodiments of apparatus for co-casting of interface nodes with 3-D printed components and is not intended to represent the only embodiments in which the invention may be practiced.

This disclosure is generally directed to Interface Nodes, which connect to cast components. The Interface Nodes may have high precision features or complex geometries that allow them to perform specific functions, including creating connections to spanning structures such as tubes, structural panels, extrusions, sheet metal, and other structural members. Stated differently, Interface Nodes are structures that incorporate one or more high precision features and that connect to other cast components to form a versatile and efficient arrangement of functional parts.

The Interface Nodes architecture may use a variety of connection features to enable coupling of the Interface Node to other components. The use of Interface Nodes to connect together preconfigured networks of cast components and spanning structures in a transport structure or other mechanized assembly has numerous advantages. Among others, the architecture disclosed in the aspects herein can streamline the manufacturing process by increasing production volume of both high-precision and lower precision parts while decreasing production costs. The Interface Nodes architecture is also robust, compact, and inherently reliable, and can therefore increase overall product quality.

Interface Nodes are generally high precision structures, meaning that they may incorporate one or more complex features and functions as described herein. These features and functions, often compactly integrated into the Interface Nodes, may be defined by numerous physical properties and characteristics. Being an often complex consolidation of structures integrated into a single component, the Interface Node may include both intricate connection features and sophisticated functional capabilities. These features and capabilities enable the Interface Node to seamlessly connect with larger, cast components without requiring a significant sacrifice in production throughput. Specifically, from the two components, the size of the Interface Node is reduced compared to the other component, or cast component in this case; to consume mass, and to reduce material consumption while printing the Interface Node.

The term “exemplary” used throughout this disclosure means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments presented in this disclosure. The detailed description includes specific details for the purpose of providing a thorough and complete disclosure that fully conveys the scope of the invention to those skilled in the art. However, the invention may be practiced without these specific details. In some instances, well-known structures and components may be shown in block diagram form, or omitted entirely, in order to avoid obscuring the various concepts presented throughout this disclosure.

The use of 3-D printing may provide significant flexibility for enabling manufacturers of mechanical structures and mechanized assemblies to manufacture parts with complex geometries. For example, 3-D printing techniques provide manufacturers with the flexibility to design and build parts having intricate internal lattice structures and/or profiles that may not be possible to manufacture via traditional manufacturing processes or may be cost prohibitive to manufacture via traditional manufacturing processes. As discussed above, the 3-D printed sub-components may need to be attached or connected to other sub-components, including other 3-D printed sub-components, extruded sub-components, or still other sub-components.

In an aspect, an interface node may be co-cast to include galvanic corrosion protection features. For example, sealants and other isolators may be used for galvanic protection. Sealants provide a hermetically sealed environment for adhesive connections between the IN and the tube/panel/extrusion. Additionally, they provide isolation by preventing physical contact between the two components, thereby reducing or eliminating the possibility of galvanic corrosion. In an aspect, however, the galvanic corrosion protection features, are not in the co-cast region. Rather, the galvanic corrosion protection features may be at an interface connecting to tubes, panels, extrusions, or other types of interface points.

FIGS. 1A-Dillustrate respective side views of an exemplary 3-D printer system. In this example, the 3-D printer system is a powder-bed fusion (PBF) system100.FIGS. 1A-Dshow PBF system100during different stages of operation. The particular embodiment illustrated inFIGS. 1A-Dis one of many suitable examples of a PBF system employing principles of this disclosure. It should also be noted that elements ofFIGS. 1A-Dand the other figures in this disclosure are not necessarily drawn to scale, but may be drawn larger or smaller for the purpose of better illustration of concepts described herein. PBF system100can include a depositor101that can deposit each layer of metal powder, an energy beam source103that can generate an energy beam, a deflector105that can apply the energy beam to fuse the powder material, and a build plate107that can support one or more build pieces, such as a build piece109. PBF system100can also include a build floor111positioned within a powder bed receptacle. The walls112of the powder bed receptacle generally define the boundaries of the powder bed receptacle, which is sandwiched between the walls112from the side and abuts a portion of the build floor111below. Build floor111can progressively lower build plate107so that depositor101can deposit a next layer. The entire mechanism may reside in a chamber113that can enclose the other components, thereby protecting the equipment, enabling atmospheric and temperature regulation and mitigating contamination risks. Depositor101can include a hopper115that contains a powder117, such as a metal powder, and a leveler119that can level the top of each layer of deposited powder.

Referring specifically toFIG. 1A, this figure shows PBF system100after a slice of build piece109has been fused, but before the next layer of powder has been deposited. In fact,FIG. 1Aillustrates a time at which PBF system100has already deposited and fused slices in multiple layers, e.g., 150 layers, to form the current state of build piece109, e.g., formed of 150 slices. The multiple layers already deposited have created a powder bed121, which includes powder that was deposited but not fused.

FIG. 1Bshows PBF system100at a stage in which build floor111can lower by a powder layer thickness123. The lowering of build floor111causes build piece109and powder bed121to drop by powder layer thickness123, so that the top of the build piece and powder bed are lower than the top of powder bed receptacle wall112by an amount equal to the powder layer thickness. In this way, for example, a space with a consistent thickness equal to powder layer thickness123can be created over the tops of build piece109and powder bed121.

FIG. 1Cshows PBF system100at a stage in which depositor101is positioned to deposit the powder117in a space created over the top surfaces of build piece109and powder bed121and bounded by powder bed receptacle walls112. In this example, depositor101progressively moves over the defined space while releasing the powder117from hopper115. Leveler119can level the released powder to form a powder layer125that has a thickness substantially equal to the powder layer thickness123(seeFIG. 1B). Thus, the powder in a PBF system can be supported by a powder material support structure, which can include, for example, a build plate107, a build floor111, a build piece109, walls112, and the like. It should be noted that the illustrated thickness of powder layer125(i.e., powder layer thickness123(FIG. 1B) is greater than an actual thickness used for the example involving150previously-deposited layers discussed above with reference toFIG. 1A.

FIG. 1Dshows PBF system100at a stage in which, following the deposition of powder layer125(FIG. 1C), energy beam source103generates an energy beam127and deflector105applies the energy beam to fuse the next slice in build piece109. In various exemplary embodiments, energy beam source103can be an electron beam source, in which case, energy beam127constitutes an electron beam. Deflector105can include deflection plates that can generate an electric field or a magnetic field that selectively deflects the electron beam to cause the electron beam to scan across areas designated to be fused. In various embodiments, energy beam source103can be a laser, in which case, the energy beam127is a laser beam. Deflector105can include an optical system that uses reflection and/or refraction to manipulate the laser beam to scan selected areas to be fused.

In various embodiments, the deflector105can include one or more gimbals and actuators that can rotate and/or translate the energy beam source to position the energy beam. In various embodiments, energy beam source103and/or deflector105can modulate the energy beam, e.g., turn the energy beam on and off as the deflector scans so that the energy beam is applied only in the appropriate areas of the powder layer. For example, in various embodiments, the energy beam can be modulated by a digital signal processor (DSP).

In an aspect, interface nodes may be manufactured through PBF and other additive manufacturing (AM) processes that may result in parts with small feature size and accurate prints. While PBF and the other AM processes used to manufacture interface nodes may offer a great degree of accuracy and the flexibility to fabricate parts with a plurality of incredibly complex features, PBF and the other AM processes may not be ideal for high throughput production. Therefore, structures that enable connection to the interface nodes may be developed to combine the great degree of accuracy and the flexibility to fabricate parts with a plurality of incredibly complex features using PBF and the other AM processes with other conventional processes. Nodes made using PBF and other AM process may connect to other structures (e.g., tubes, extrusions, panels, or other conventionally manufactured processes). Such a node may be connected to the other structures (e.g., tubes, extrusions, panels, or other conventionally manufactured processes).

FIG. 2is a diagram illustrating an example node200that may be a co-casting. As illustrated, an additively manufactured component202may include co-cast components206. The co-cast component206may in some aspects, form the node200. The node200may be an additively manufactured node202that connects to other structures in a vehicle chassis or other higher level assembly (e.g., a tube208). Other structures (e.g., a tube208) may connect to the additively manufactured node202. The other structures (e.g., a tube208) may include structural tubes (carbon fiber composite, metal, alloys, and those made of other engineering materials), extrusions, panels, sheet metals, castings and other machined components (not illustrated). Machining may include milling, boring, tapping, grinding, or other types of machining.

The additively manufactured component202may be placed in a casting mold. (SeeFIGS. 5-7for examples of casting molds.) In an aspect, the additively manufactured component202may be secured to the casting mold such that the node200(e.g., additively manufactured component202) is constrained, e.g., unable to move or rotate during the casting process. For example, the node200may be constrained be the shape of the node200or an anti-rotation feature204of the node200, e.g., on the additively manufactured component202of node200. (For example, the node200may have a hexagonally shaped base that may form the anti-rotation feature204.)

In an aspect, the casting mold accepts the additively manufactured component202). In an aspect, the additively manufactured component202may be an interface node. The node200(e.g., additively manufactured component202) may be placed in a mold configured to accept the node200(e.g., additively manufactured components202). The node200may have a co-casting region206. The co-cast region206refers to the part of the node200that would cooperate with the casting cavity to form a part. The co-cast region206could be fins or fingers extending into the cast cavity to increase the surface area of the joint between the node and the casting. These features, additionally, could serve as structures for optimal load or heat transfer into the cast part. Therefore, all the complexity could be built into the node while the casting could be a part with a simple geometry. Furthermore, the increased surface area of the node can improve the blend between the node and the cast part. The increased surface area may be provided by an engineered surface. The engineered surfaces may be shapes other than flat surfaces. Engineered surfaces may be provided in lieu of flat surfaces.

In an aspect for this process, the melting point/glass transition temperature (e.g., for plastics) of the node200(e.g., additively manufactured component202) may be higher than that of the material being cast. In an aspect, the additively manufactured components202may be secured to the mold using mechanical fastening features.

In an aspect, the node may have stand-off tabs that would enable the node to be fixtured in place during the casting process. For example, the anti-rotation feature204may also function as a stand-off tab. The node may have other features for fixturing during the casting process. In an aspect, the other features may include pins (e.g., anti-rotation feature204) or grooves to accept pins/tongues. The pins/tongues may additionally serve as locating features to locate the node in the mold (e.g., either on the exterior of the mold or the interior).

The additively manufactured components202may be an Interface Node. As illustrated inFIG. 2, the additively manufactured components202includes the adhesive inlet port210, the adhesive outlet port212, and sealants. In an embodiment, the adhesive outlet port212may be connected to a negative pressure source (such as a vacuum source), to promote adhesive distribution during the injection process. In addition, grooves or other features may be provided on the additively manufactured components202(e.g., Interface Node) to accept sealants, and other isolators. Sealants may be used to provide a hermetically sealed enclosure for the adhesive introduction, and would further ensure the integrity of the adhesive once it has cured. Sealants also ensure that the additively manufactured components202and the component the additively manufactured components202is being connected to do not come under physical contact, thereby preventing potential galvanic corrosion issues. In some cases, features to accept isolators may be co-printed with the additively manufactured components202. The isolators would ensure that the additively manufactured components202and the component being connected to the additively manufactured components202do not come in physical contact with each other, thereby preventing galvanic corrosion. In an aspect, nylon washers may be used as isolators.

While a node to tube208connection is illustrated on additively manufactured components202, it will be appreciated by those skilled in the art that any connection feature may be present on the additively manufactured components202, as mandated by the requirements of a particular design. For example, the additively manufactured components202(e.g., Interface Node) may have a node to panel connection feature or other types of connections.

Co-casting of Interface Nodes may allow designs to realize multi-material connections. Without Interface Nodes, cast components might have to undergo prohibitively expensive and time-consuming machining operations to obtain the intricate features to realize robust, multi-material connections.

FIG. 3is a diagram300illustrating an example cast part302and node304. The diagram300illustrates a node304attached to a mold306having a casting cavity. The node304may be fitted internal to the mold306(see, e.g.,FIG. 5), or external. The node304may be a hybrid fit (see, e.g.,FIG. 6), wherein a part of the node304may remain internal to the mold, while the other part would remain external during the casting process.

FIG. 4is a diagram illustrating an example node400that may be a co-casting. As illustrated, an additively manufactured component402may include co-cast components406. The co-cast component406may in some aspects, form the node400. The node400may be an additively manufactured node402that connects to other structures in a vehicle chassis or other higher level assembly (e.g., a tube408). Other structures (e.g., a tube408) may connect to the additively manufactured node402. The other structures (e.g., a tube408) may include structural tubes (carbon fiber composite, metal, alloys, and those made of other engineering materials), extrusions, panels, sheet metals, castings and other machined components (not illustrated). Machining may include milling, boring, tapping, grinding, or other types of machining.

The additively manufactured component402may be placed in a casting mold. (SeeFIGS. 5-7for examples of casting molds.) In an aspect, the additively manufactured component402may be secured to the casting mold such that the node400(e.g., additively manufactured component402) is constrained, e.g., unable to move or rotate during the casting process. For example, the additively manufactured component402may include a flange404with holes that may each receive a bolt or another mechanical fastening feature to mount the node400to another component (not shown) and/or to secure the additively manufactured component402to a mold (seeFIG. 5-6).

In an aspect, the casting mold accepts the additively manufactured component402). In an aspect, the additively manufactured component402may be an interface node. The node400(e.g., additively manufactured component402) may be placed in a mold configured to accept the node400(e.g., additively manufactured components402). The node400may have a co-casting region410. The co-cast region410refers to the part of the node400that would cooperate with the casting cavity to form a part. The co-cast region410could be fins or fingers412extending into the cast cavity to increase the surface area of the joint between the node and the casting. These features, additionally, could serve as structures for optimal load or heat transfer into the cast part. Therefore, all the complexity could be built into the node while the casting could be a part with a simple geometry. Furthermore, the increased surface area of the node can improve the blend between the node and the cast part. The increased surface area may be provided by an engineered surface. The engineered surfaces may be shapes other than flat surfaces. Engineered surfaces may be provided in lieu of flat surfaces.

In an aspect for this process, the melting point/glass transition temperature (e.g., for plastics) of the node400(e.g., additively manufactured component402) may be higher than that of the material being cast. In an aspect, the additively manufactured components402may be secured to the mold using mechanical fastening features.

In an aspect, the node may have stand-off tabs that would enable the node to be fixtured in place during the casting process. For example, the anti-rotation feature408may also function as a stand-off tab. The node may have other features for fixturing during the casting process. In an aspect, the other features may include pins (e.g., anti-rotation feature408) or grooves406to accept pins/tongues. The pins/tongues may additionally serve as locating features to locate the node in the mold (e.g., either on the exterior of the mold or the interior).

The additively manufactured components402may be an Interface Node. As illustrated inFIG. 4, the additively manufactured components402includes the adhesive inlet port410, the adhesive outlet port412, and sealants. In an embodiment, the adhesive outlet port412may be connected to a negative pressure source (such as a vacuum source), to promote adhesive distribution during the injection process. In addition, grooves or other features may be provided on the additively manufactured components402(e.g., Interface Node) to accept sealants, and other isolators. Sealants may be used to provide a hermetically sealed enclosure for the adhesive introduction, and would further ensure the integrity of the adhesive once it has cured. Sealants also ensure that the additively manufactured components402and the component the additively manufactured components402is being connected to do not come under physical contact, thereby preventing potential galvanic corrosion issues. In some cases, features to accept isolators may be co-printed with the additively manufactured components402. The isolators would ensure that the additively manufactured components402and the component being connected to the additively manufactured components402do not come in physical contact with each other, thereby preventing galvanic corrosion. In an aspect, nylon washers may be used as isolators.

While a node to tube408connection is illustrated on additively manufactured components402, it will be appreciated by those skilled in the art that any connection feature may be present on the additively manufactured components402, as mandated by the requirements of a particular design. For example, the additively manufactured components402(e.g., Interface Node) may have a node to panel connection feature or other types of connections.

FIG. 5is a diagram illustrating an example component500including a cast part502and a node504in a casting mold506. The node504may be fitted internal to the mold506. As discussed above, features to connect the node504to the mold506may be additively manufactured with the node504. The node504may have co-casting features508extending into the cast part502. The casting process may involve a molten metal solidifying around the co-casting feature or features508.

As illustrated inFIG. 5, the node504may include O-rings510to create a seal so that a vacuum may be drawn to cause adhesive to flow through channels512into the node504through adhesive inlet and outlet ports.

As described herein, Interface Nodes may includes adhesive inlet and outlet ports, and sealants. In an aspect, the adhesive outlet port may be connected to a negative pressure source (such as a vacuum source), to promote adhesive distribution during the injection process. In addition, grooves or other features may be provided on the Interface Node to accept sealants, and other isolators. Sealants may be used to provide a hermetically sealed enclosure for the adhesive introduction, and would further ensure the integrity of the adhesive once it has cured. Sealants also ensure that the Interface Node and the component it is being connected to do not come under physical contact, thereby preventing potential galvanic corrosion issues. In some cases, features to accept isolators may be co-printed with the Interface Node. The isolators would ensure that the Interface Node and the component being connected to the Interface Node do not come in physical contact with each other, thereby preventing galvanic corrosion. In an embodiment, nylon washers may be used as isolators.

While a node to tube connection is shown on this Interface Node at X, it would be appreciated by those skilled in the art that any connection feature may be present on the Interface Node, as mandated by the requirements. For example, the Interface Node could have a node to panel connection feature.

FIG. 6is a diagram illustrating an example component600including a cast part602and a node604in a casting mold606. The node604may be fitted partially internal to the mold606. For example, the node604may have co-casting features608extending into the cast part502. The co-casting feature608may have an engineered surface at location616. For example, in place of the flat surface at the location616illustrated inFIG. 5, an engineered surface such as engineered surfaces illustrated with respect toFIGS. 8A-8Ediscussed below may be at the location616. As discussed above, features to connect the node604to the mold606may be additively manufactured with the node604. In an aspect, the casting process may involve a molten metal solidifying around the co-casting feature or features608.

As illustrated inFIG. 6, the node604may include O-rings610to create a seal so that a vacuum may be drawn to cause adhesive to flow through channels612into the node604through adhesive inlet and outlet ports. Additionally, as illustrated inFIG. 6, the node604may include a flange614. The flange614may be the same or similar to the flange404ofFIG. 4. The flange614may include holes that may each receive a mechanical fastening feature to mount the node400to another component (not shown) and/or to secure the node604to a mold.

FIG. 7is a diagram illustrating an example cutaway of a component700including a cast part702and a node704in a casting mold706. As discussed above with respect toFIG. 5, the node704may be fitted partially internal to the mold706. For example, the node704may have co-casting features708extending into the cast part702. As discussed above, features to connect the node704to the mold706may be additively manufactured with the node704. In an aspect, the casting process may involve a molten metal solidifying around the co-casting feature or features708. The co-casting feature708may be a flat surface (as illustrated inFIGS. 5-6) or may be an engineered surface. Example engineered surfaces are illustrated inFIGS. 8A-8E.

In an aspect, the node704may be an interface node. The node704may include an adhesive port710and a vacuum port712. The interface node may provide an interface to a tube716. The tube716and the interface node (node704) may provide a sealable connection using O-rings716, which would be placed in grooves co-printed with the Interface Node.

FIG. 8Ais a close up view of Interface Nodes811ahaving an engineered surface at a co-casting region, e.g., the area of the interface node where the co-casting occurs. In accordance with this embodiment, the surfaces of the Interface Nodes811ahave been additively manufactured to include complex engineered surfaces820a.

FIG. 8Bis a close up view of Interface Nodes811bhaving an engineered surface at a co-casting region, e.g., the area of the interface node where the co-casting occurs. In accordance with this embodiment, the surfaces of the Interface Nodes811bhave been additively manufactured to include complex engineered surfaces820b.

FIG. 8Cis a close up view of Interface Nodes811chaving an engineered surface at a co-casting region, e.g., the area of the interface node where the co-casting occurs. In accordance with this embodiment, the surfaces of the Interface Nodes811chave been additively manufactured to include complex engineered surfaces820c.

FIG. 8Dis a close up view of Interface Nodes811dhaving an engineered surface at a co-casting region, e.g., the area of the interface node where the co-casting occurs. In accordance with this embodiment, the surfaces of the Interface Nodes811dhave been additively manufactured to include complex engineered surfaces820d.

FIG. 8Eis a close up view of Interface Nodes811ehaving an engineered surface at a co-casting region, e.g., the area of the interface node where the co-casting occurs. In accordance with this embodiment, the surfaces of the Interface Nodes811ehave been additively manufactured to include complex engineered surfaces820e.

In an aspect, the engineered surfaces illustrated inFIGS. 8A-8Emay each be configured to significantly improve a connection between the Interface Nodes811a-811eand a cast part (502,602,702). The engineered surfaces may be fingers822ethat may provide an increased surface area for the casting (cast part502,602,702) to interface with the Interface Node. Increasing surface area may improve the blend between the node (e.g., interface node811e) and the cast part502,602,702. Furthermore, in embodiments where the melting point of the interface node811a-811eis not significantly higher or the melting point of the interface node811a-811eis similar to that of the casting (e.g., the cast part502,602,702), the engineered surfaces may melt and solidify within what may be a higher strength interface node811ematerial. Other embodiments may use a higher strength material as an interface node811e. The strength requirements of the interface between the interface node811eand the casting (e.g., the cast part502,602,702) may mandate the use of a higher strength material.

FIG. 9is a flowchart900illustrating an example method in accordance with the systems and methods described herein. At block902, manufacture, e.g., additively manufacture, a node. For example, additively manufacture a node (202,304,402,504,604,704). In an aspect, the additively manufactured node (202,304,402,504,604,704) may include an interface node811a-811e.

In another aspect, forming the additively manufacturing the interface node may include forming at least one of a node-to-tube connection, node-to-extrusion connection, or a node-to-panel connection.

At block904, (optional) the method may include additively manufacturing a pattern such as a mold506,606. A part may be cast using the pattern, e.g., the mold506,606. For example, the method may include additively manufacturing a pattern such as a mold506,606. A part may be cast using the pattern, e.g., the mold506,606. For example, block906may, in some examples, be performed using the pattern, e.g., the mold506,606, additively manufacturing at block904.

At block906, cast a part onto the additively manufactured node. For example, casting a part (e.g., cast part502,602,702) onto the additively manufactured node (202,304,402,504,604,704). In an aspect, an additively manufactured node (202,304,402,504,604,704) may be placed in a mold (506,606). The additively manufactured node (202,304,402,504,604,704) may be entirely contained by the mold (506). Alternatively, the additively manufactured node (202,304,402,504,604,704) may be partially contained by the mold (606). Material may be added to the mold (506,606) to create the casting, e.g., the cast part502,602,702. In an aspect, the cast part502,602,702may be aluminum and the additively manufactured node (202,304,402,504,604,704) may include one of steel or titanium. The additively manufactured node (202,304,402,504,604,704) and the cast part502,602,702may form a single co-cast part (e.g., component500,600,700). The additively manufactured node (202,304,402,504,604,704) may include an engineered surface that may form a connection to the cast part.

An aspect may include means for additively manufacturing a node, e.g., (as illustrated inFIG. 1A-1D). An aspect may include means for casting a part onto the additively manufactured node, e.g., as illustrated inFIGS. 2 and 4.

The previous description is provided to enable any person skilled in the art to practice the various aspects described herein. Various modifications to these exemplary embodiments presented throughout this disclosure will be readily apparent to those skilled in the art, and the concepts disclosed herein may be applied to apparatus for co-casting of interface nodes with 3-D printed components. Thus, the claims are not intended to be limited to the exemplary embodiments presented throughout the disclosure but are to be accorded the full scope consistent with the language claims. All structural and functional equivalents to the elements of the exemplary embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. § 112(f), or analogous law in applicable jurisdictions, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”