ADDITIVELY-MANUFACTURED COMPONENT HAVING AT LEAST ONE STIFFENING MEMBER AND METHOD OF FORMING THE SAME

An additively-manufactured component includes a main body, and at least one stiffening member. Each of the main body and the stiffening member(s) is additively manufactured layer-by-layer in a common build direction. A method of forming an additively-manufactured component includes forming a main body and at least one stiffening member of the additively-manufactured component layer-by-layer in a common build direction.

FIELD OF THE DISCLOSURE

Embodiments of the present disclosure generally relate to additive-manufacturing systems and methods, and more particularly, to systems and methods of additively-manufacturing components having at least one stiffening member.

BACKGROUND OF THE DISCLOSURE

Additive manufacturing systems and methods are used to fabricate components (such as parts or products) through multiple layers of material. For example, known additive manufacturing systems and methods form a component by adding layer-upon-layer of material. Additive manufacturing systems and methods may include or otherwise use three dimensional (3D) modeling (for example, computer-aided design or CAD) software, computer-controlled additive-manufacturing equipment, and raw materials in powder or liquid form.

Additive manufacturing encompasses a wide variety of technologies and incorporates a wide variety of techniques, such as, for example, laser freeform manufacturing (LFM), laser deposition (LD), direct metal deposition (DMD), laser metal deposition, laser additive manufacturing, laser engineered net shaping (LENS), stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), multi jet modeling (MJM), 3D printing, rapid prototyping, direct digital manufacturing, layered manufacturing, and additive fabrication. Moreover, a variety of raw materials may be used in additive manufacturing to create products. Examples of such materials include plastics, metals, concrete, and glass.

One example of an additive-manufacturing system is a laser additive-manufacturing system. Laser additive manufacturing includes spraying or otherwise injecting a powder or a liquid into a focused beam of a high-power laser ornexusof a plurality of high-powered lasers under controlled atmospheric conditions, thereby creating a weld pool. The resulting deposits may then be used to build or repair articles for a wide variety of applications. The powder injected into the high-power laser beam may include a wide variety of materials such as metal, plastic, and/or the like.

Many structural panels (particularly with respect to aerospace applications) include an orthogrid or isogrid support structure. Such supports typically include a first set of parallel ribs and a second set of parallel ribs that are orthogonal to the first set of parallel ribs. That is, the first set of parallel ribs are typically perpendicular to the second set of parallel ribs.

However, additively manufactured panels having orthogrid or isogrid support structures are typically formed through labor intensive, time intensive, and costly processes. For example, orthogonal ribs perpendicular to a build direction typically have to be supported during the manufacturing process with additional support material. The additional support material may be costly, both in terms of material cost and additional build time. Further, after the build is completed, the excess material has to be machined away to refine the part into final form. Again, such additional steps may be costly and may take time.

SUMMARY OF THE DISCLOSURE

A need exists for a system and method of efficiently forming a structural component through an additive manufacturing process. Further, a need exists for an additively-manufactured component having at least one stiffening member that is efficiently formed.

With those needs in mind, certain embodiments of the present disclosure provide an additively-manufactured component that includes a main body, and at least one stiffening member. Each of the main body and the at least one stiffening member is additively manufactured layer-by-layer in a common build direction. The main body and the at least one stiffening member may be devoid of isogrid or orthogrid supports.

In at least one embodiment, an additive manufacturing head is configured to emit energy into a powder bed to form layers of the main body and the at least one stiffening member in the common build direction. In at least one embodiment, the main body and the at least one stiffening member form an offtake for an engine. The main body and the least one stiffening member may be formed of Titanium.

The additively-manufactured component may also include at least one longitudinal rib that extends along at least a portion of a length of the main body. The additively-manufactured component may be devoid of orthogonal ribs that orthogonally couple to the at least one longitudinal rib. A depth of the at least one stiffening member is greater than a depth of the at least one longitudinal rib.

In at least one embodiment, the at least one stiffening member includes a flattened protuberance that upwardly extends from the main body. The at least one stiffening member may include a first stiffening member and a second stiffening member. The first stiffening member may be sized and shaped differently than the second stiffening member. The first stiffening member may be at or proximate to an end, and the second stiffening member may be between the end and a distal tip.

In at least one embodiment, a depth of the at least one stiffening member is greater than a height of the at least one stiffening member.

Certain embodiments of the present disclosure provide a method of forming an additively-manufactured component. The method includes forming a main body and at least one stiffening member of the additively-manufactured component layer-by-layer in a common build direction. The forming may include emitting energy from an additive manufacturing head into a powder bed to form layers of the main body and the at least one stiffening in the common build direction.

DETAILED DESCRIPTION OF THE DISCLOSURE

Certain embodiments of the present disclosure provide an additively-manufactured component having at least one stiffening member. The stiffening member is formed via an additive manufacturing process, layer-by-layer, in the direction of build, as opposed to perpendicular to the direction of build. The additively-manufactured component may be devoid of isogrid or orthogrid supports. The stiffening member may be a flattened protuberance, such as a support panel.

The stiffening member(s) provide stiffness to the additively-manufactured component. The stiffening member(s) are vertically formed, layer-by-layer. Accordingly, the additively-manufactured component may be formed without isogrid or orthogrid supports, exhibit a desired stiffness (via the stiffening member(s)), and may be efficiently and cost-effectively formed.

Certain embodiments of the present disclosure provide a method of supporting a component (such as a complex thin membrane) that attaches to a pressurized vessel (such as a housing of an engine of an aircraft). In at least one embodiment, the component may be an offtake that is to be positioned within a housing of an engine.

FIG. 1illustrates a schematic diagram of an additive manufacturing system100, according to an embodiment of the present disclosure. The additive manufacturing system100includes a container102that includes a base104and walls106upstanding from the base104. The base104and the walls106define a forming chamber108. The forming chamber108retains a powder bed110, such as formed of metal, polymer, or other such material.

An additive manufacturing head112is fixed in position or moveable in relation to the forming chamber108. The additive manufacturing head112includes an energy emitter114that emits energy116into the powder bed110to form a component118, layer-by-layer, from a base surface120towards an upper surface122in a build direction123. As shown, the build direction123may be a vertical direction that extends upwardly from the base104within the forming chamber108. In at least one embodiment, the additive manufacturing head112is a laser scanner that emits the energy116as one or more laser beams through the energy emitter114, which may be a laser output, array, and/or the like. Optionally, the additive manufacturing head112may be an electron beam scanner that emits one or more electron beams through the energy emitter114, which may be an electron beam output, array, and/or the like. As another example, the additive manufacturing head112may be an arcing scanner that emits electrical arcing energy through the energy emitter114, which may be an arcing output, array, and/or the like. U.S. Pat. No. 9,751,260, entitled “Additive Manufacturing Systems, Apparatuses, and Methods” discloses examples of an additive manufacturing head.

The additive manufacturing head112is configured to emit energy, such as one or more laser beams, into the powder bed110to form layers of the component118from the base surface120upwardly towards the upper surface122in the build direction123. For example, the additive manufacturing head112may be configured to selectively laser sinter layers of material of the powder bed110onto an existing lower layer of material to form the component118.

The additive manufacturing head112also forms one or more stiffening members124on or within a main body129of the component118in the build direction123. The stiffening members124are integrally formed with the main body129of the component118. The stiffening member(s)124are formed layer-by-layer in the build direction123. The component118may be devoid of ribs that are orthogonal to the build direction123and/or the stiffening members124. For example, the component118may be devoid of ribs that span across the component118and orthogonally intersect or otherwise connect to the stiffening members124. The stiffening members124are formed layer-by-layer through an additively manufactured process (such as via the additive manufacturing head112emitting the energy116into the powder bed110) in the build direction123, in contrast to a direction125that is perpendicular to the build direction123.

In at least one embodiment, the additive manufacturing system100includes a forming control unit126, which may be configured to control (for example, operate) the additive manufacturing system100. The forming control unit126may be in communication with the additive manufacturing head112, such as through one or more wired or wireless connections. The forming control unit126may be configured to operate the additive manufacturing system100through preprogrammed instructions stored in memory.

In operation, the additive manufacturing head112emits the energy116(such as one or more laser beams) into the powder bed110to form layers128of the component118, thereby forming the component118from the base surface120to the upper surface122in a layer-by-layer manner in the build direction123. For example, the additive manufacturing head112selectively laser sinters the layers128from material within the powder bed110onto previously-formed existing layers128. The stiffening members124of the component118are formed in the same manner. That is, layers130of the stiffening members124are additively-manufactured in the build direction123via the additive manufacturing head112emitting the energy116into the powder bed110. The forming control unit126may control the additive manufacturing head112during the forming process.

The stiffening members124are integrally formed with the additively-manufactured component118through the additive manufacturing system100and additive manufacturing process. That is, the stiffening members124are integrally formed with the main body129of the additively-manufactured component118. The stiffening members124are not grids, ribs, inserts, or the like over which another material is molded or coupled.

The additively-manufactured component118includes the main body129and the stiffening member(s)124. Each of the main body129and the stiffening member(s)124is additively manufactured layer-by-layer in the common build direction123.

In at least one embodiment, the component118may be formed through a freeform method, which may not include a powder bed. Instead, the powder may be blown directly onto the energy emitted from the additive manufacturing head to form the component118.

As used herein, the term “control unit,” “central processing unit,” “unit,” “CPU,” “computer,” or the like may include any processor-based or microprocessor-based system including systems using microcontrollers, reduced instruction set computers (RISC), application specific integrated circuits (ASICs), logic circuits, and any other circuit or processor including hardware, software, or a combination thereof capable of executing the functions described herein. Such are exemplary only, and are thus not intended to limit in any way the definition and/or meaning of such terms. For example, the forming control unit126may be or include one or more processors that are configured to control operation of the additive manufacturing system100, as described herein.

The forming control unit126is configured to execute a set of instructions that are stored in one or more data storage units or elements (such as one or more memories), in order to process data. For example, the forming control unit126may include or be coupled to one or more memories. The data storage units may also store data or other information as desired or needed. The data storage units may be in the form of an information source or a physical memory element within a processing machine.

The diagrams of embodiments herein may illustrate one or more control or processing units, such as the forming control unit126. It is to be understood that the processing or control units may represent circuits, circuitry, or portions thereof that may be implemented as hardware with associated instructions (e.g., software stored on a tangible and non-transitory computer readable storage medium, such as a computer hard drive, ROM, RAM, or the like) that perform the operations described herein. The hardware may include state machine circuitry hardwired to perform the functions described herein. Optionally, the hardware may include electronic circuits that include and/or are connected to one or more logic-based devices, such as microprocessors, processors, controllers, or the like. Optionally, the forming control unit126may represent processing circuitry such as one or more of a field programmable gate array (FPGA), application specific integrated circuit (ASIC), microprocessor(s), and/or the like. The circuits in various embodiments may be configured to execute one or more algorithms to perform functions described herein. The one or more algorithms may include aspects of embodiments disclosed herein, whether or not expressly identified in a flowchart or a method.

As used herein, the terms “software” and “firmware” are interchangeable, and include any computer program stored in a data storage unit (for example, one or more memories) for execution by a computer, including RAM memory, ROM memory, EPROM memory, EEPROM memory, and non-volatile RAM (NVRAM) memory. The above data storage unit types are exemplary only, and are thus not limiting as to the types of memory usable for storage of a computer program.

FIG. 2illustrates a perspective top view of an additively-manufactured component118, according to an embodiment of the present disclosure.FIG. 3illustrates a top view of the additively-manufactured component118. Referring toFIGS. 2 and 3, the additively-manufactured component118may be an offtake for an engine of an aircraft. The additively-manufactured component118may be formed of a metal, such as Titanium. The additively-manufactured component118is formed by an additive manufacturing system, such as the additive manufacturing system100shown and described with respect toFIG. 1.

The additively-manufactured component118includes the base surface120connected to the top surface122through a plurality of layers that are formed by the additive manufacturing system. The additively-manufactured component118includes stiffening members124.

As shown, the additively-manufactured component118may include a plurality of longitudinal ribs138. The ribs138extend along at least a portion of the length139of the additively-manufactured component118. The additively-manufactured component118may be devoid of ribs that are orthogonal to the ribs138. In at least one embodiment, the additively-manufactured component118may include more or less longitudinal ribs138than shown. In at least one embodiment, the additively-manufactured component118may not include any longitudinal ribs138.

The stiffening members124may be flattened protuberances127that upwardly extend from a main body129of the additively-manufactured component118. For example, the flattened protuberances127may be panels, straps, collars, sheaths, or the like. The stiffening members124provide rigidity and stiffness to the additively-manufactured component118without the need for orthogonal latitudinal ribs that are perpendicularly oriented in relation to the longitudinal ribs138.

As shown, the depths140of the stiffening members124are substantially greater than the depths141of the longitudinal ribs138. For example, the depths140of the stiffening members124may be five times, ten times, or even more the depths141of the longitudinal ribs138.

As shown, the additively-manufactured component118may include first and second stiffening members124. The stiffening members124may be sized and shaped differently. In at least one other embodiment, the stiffening members124may be sized and shaped the same. One of the stiffening members124may be at and/or proximate an end142of the additively-manufactured component118, and the other stiffening member124may be between the end142and a distal tip144of the additively-manufactured component118. Optionally, the stiffening members124may be positioned at different areas of the additively-manufactured component118.

The additively-manufactured component118may have more or less stiffening members124than shown. For example, the additively-manufactured component118may be one stiffening member124. Optionally, the additively-manufactured component118may have three or more stiffening members124. As described above, the additively-manufactured component118including the stiffening member(s)124is formed layer-by-layer in the build direction123. In at least one embodiment, the additively-manufactured component118is devoid of latitudinal ribs, such as which would otherwise orthogonally intersect or otherwise connect to at least one of the longitudinal ribs138.

As shown, heights147of the ribs138are substantially greater than the depths141of the ribs138. For example, the heights147may be five to ten times the depths141. In contrast, the heights149of the stiffening members124are substantially less than the depths140of the stiffening members124. For example, the depths140may be five to ten times greater than the heights149. In short, the heights147of the ribs138are greater than the depths141of the ribs138, while the depths140of the stiffening members124are greater than the heights149of the stiffening members124.

The stiffening members124provide sufficient rigidity and stiffness to the additively-manufactured component118without the need for latitudinal ribs (or even the longitudinal ribs138). Because the stiffening members124are formed through the additively-manufactured system100and process in the build direction123, there is no need to reposition the additively-manufactured component118during the build process. Further, there is no need to provide numerous support structures to form numerous ribs. Moreover, there is no need for extensive post-processing steps to machine overhanging portions of isogrid or orthogrid supports. As such, the additively-manufactured component118provides sufficient rigidity and stiffness (via the stiffening member(s)124) and is formed through an efficient and cost-effective additive manufacturing process.

FIG. 4illustrates a perspective internal view of a portion of a barrel200having the additively-manufactured component118secured thereto, according to an embodiment of the present disclosure. As indicated, the additively-manufactured component118may be an offtake, and the barrel200may form a portion of a housing of an engine of an aircraft.

The barrel200may include a composite outer skin202, and arcuate inner metal (such as Aluminum) skin clips204. The additively-manufactured component118may include an aft upstanding flange205that is configured to contact another structure (not shown). Fasteners may be used to secure the additively-manufactured component118to the skin clips204at bearing surfaces160. The distal tip144is tapered in relation to the end142to provide an aerodynamic shape that is configured to channel air therethrough. In at least one embodiment, the barrel200includes mirrored portions, such that opposed, mirrored additively-manufactured components118are secured therein.

FIG. 5illustrates a flow chart of a method of forming an additively-manufactured component, according to an embodiment of the present disclosure. Referring toFIGS. 1 and 5, at300, the forming control unit126operates the additive manufacturing head112to emit the energy116into the powder bed110to form the layers128of the additively-manufactured component118in the build direction123. At302, the forming control unit126operates the additive manufacturing head112to form layers of one or more stiffening members124(such as on or within a main body) in the build direction123.

In a least one embodiment, a method of forming an additively-manufactured component118includes forming the main body129and the stiffening member(s)124of the additively-manufactured component118layer-by-layer in the common build direction123. The forming may include emitting energy116from the additive manufacturing head112into the powder bed110to form layers128and130of the main body129and the stiffening member(s)124in the common build direction123.

The method may also include forming at least one longitudinal rib138that extends along at least a portion of a length139of the main body129. The forming the main body129and the stiffening member124may include forming the stiffening member(s)124with a depth140that is greater than a depth141of the longitudinal rib(s)138.

The forming the main body129and the stiffening member(s)124may include forming the stiffening member(s)124as a flattened protuberance that upwardly extends from the main body129. The forming the main body129and the stiffening member(s)124may include forming a first stiffening member124and a second stiffening member124.

In at least one embodiment, the forming the main body129and the stiffening member(s)124includes forming the stiffening member(s)124to have a depth140is greater than a height149.

Referring toFIGS. 1-5, in at least one embodiment, the main body and the stiffening members may be formed simultaneously. Further, in at least one embodiment, the component may be formed through a freeform method, which may not include a powder bed. Instead, the powder may be blown directly onto the energy emitted from the additive manufacturing head to form the component.

As described herein, embodiments of the present disclosure provide systems and methods of efficiently forming components having support structures through an additive manufacturing process. Further, embodiments of the present disclosure provide additively-manufactured components having at least one stiffening member that is efficiently formed.