Abstract:
Embodiments are directed to a method for manufacturing a product comprising: establishing, by a computing device comprising a processor, at least one parameter of a particular instance of a component to be used in the product, adapting, by the computing device, a baseline model of the component based on the at least one parameter to accommodate use of the particular instance of the component, growing a structure based on the adapted model to accommodate the particular instance of the component using an additive manufacturing technique, coupling the structure to the particular instance of the component, growing an electrical harness by using additive printing to establish an electrical cable, and assembling the product by coupling the electrical harness to the particular instance of the component.

Description:
BACKGROUND 
       [0001]    The present disclosure relates to computing technology, and more specifically, to generation of cables, leads, and shielding for purposes of conveying data. 
         [0002]    Rapid manufacturing is challenging to achieve without sacrificing quality. In order to reduce cost and manufacturing time, it may be possible to leverage commercial-off-the-shelf (COTS) components, combining such components to enable a new system of capabilities. Such a technique is driven by a concept that low cost and rapid turn is achievable by limiting research and development (R&amp;D) activities, with a focus being placed on integration. However, in a dynamic COTS environment where new products emerge on the order of, e.g., twelve to eighteen months, simply focusing on integration is infeasible and impractical. 
       SUMMARY 
       [0003]    According to one embodiment, a method for manufacturing a product comprises: establishing, by a computing device comprising a processor, at least one parameter of a particular instance of a component to be used in the product, adapting, by the computing device, a baseline model of the component based on the at least one parameter to accommodate use of the particular instance of the component, growing a structure based on the adapted model to accommodate the particular instance of the component using an additive manufacturing technique, coupling the structure to the particular instance of the component, growing an electrical harness by using additive printing to establish an electrical cable, and assembling the product by coupling the electrical harness to the particular instance of the component. 
         [0004]    According to another embodiment, a method comprises: establishing connecting pins for an electrical cable by sintering, creating wiring in the cable by using ink printing to connect the pins, wherein at least a portion of the wiring is configured to convey data, creating shielding atop the wiring using ink printing, and creating a mechanical protection and interface for the cable using three-dimensional (3D) printing. 
         [0005]    According to another embodiment, an electrical cable comprises: connecting pins established by ether sintering, wiring connecting the pins established by ink printing, wherein at least a portion of the wiring is configured to convey data, shielding atop the wiring established by ink printing, and mechanical protection for the wiring established by three-dimensional (3D) printing. 
         [0006]    Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with the advantages and the features, refer to the description and to the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0007]    For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts: 
           [0008]      FIG. 1  illustrates a flow chart of an exemplary method; 
           [0009]      FIGS. 2A-2E , taken together, illustrate an exemplary sequence used to establish a harness or cable; 
           [0010]      FIG. 3A  illustrates a connector mounted to an additive cable in accordance with an exemplary embodiment; 
           [0011]      FIG. 3B  illustrates a connector mounted to an additive cable in accordance with an exemplary embodiment; 
           [0012]      FIG. 4  illustrates a flow chart of an exemplary method; and 
           [0013]      FIGS. 5A-5B  illustrate an exemplary product manufactured in accordance with one or more embodiments. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    It is noted that various connections are set forth between elements in the following description and in the drawings (the contents of which are included in this disclosure by way of reference). It is noted that these connections in general and, unless specified otherwise, may be direct or indirect and that this specification is not intended to be limiting in this respect. In this respect, a coupling between entities may refer to either a direct or an indirect connection. 
         [0015]    Exemplary embodiments of apparatuses, systems, and methods are described for creating custom, additive printable cables, leads, and shielding to carry data. In some embodiments, a connector may be additively grown to couple the cable to a device. In some embodiments, a cable or harness may be grown directly on top of a system structure in order to increase robustness and space utilization while reducing flex damage. 
         [0016]    Referring to  FIG. 1 , a flow chart of a method  100  is shown. The method  100  may be used to rapidly manufacture a product with structural and functional integrity, potentially on the basis of one or more components. The product may be targeted to, e.g., a commercial sector, an industrial sector, an aerospace sector, or a military sector. 
         [0017]    In block  102 , a parametric model may be established. For example, the parametric model may be established for one or more components or devices, such as a COTS component that is to be modified or adapted to support a specified function. As part of block  102 , a robotic inspection station may collect data on the three-dimensional ( 3 D) geometry, weight, and center-of-gravity (CG) of the component. 
         [0018]    In block  104 , a current state of the component, as indicated via the parametric model of block  102 , may be compared to a baseline version of the component or model. Digital data may be adapted to create a new custom design to accommodate the component in hand. 
         [0019]    In block  106 , one or more structures may be grown. Additive manufacturing techniques may be applied in connection with block  106 . Thermal management consideration may be applied in block  106 . One or more component mounting features or structures may be obtained in block  106 . 
         [0020]    In block  108 , one or more electrical harnesses may be grown. Additive printing may be used to add electrical cabling and connectors. As part of block  108 , the harness(es) may be interfaced to the structure(s) of block  106 . 
         [0021]    In block  110 , one or more build items may be delivered to an assembly cell (e.g., a robotic assembly cell). The build items may include one or more of: a housing, structures (e.g., the structures of block  106 ), a card or circuit board, and optics. 
         [0022]    In block  112 , the build items may be assembled in the assembly cell to generate the product. Additive components and harnessing may be designed to maximize robotic automation and provide a level of assurance regarding the product. 
         [0023]    In block  114 , the product may be subjected to one or more tests to validate that the product meets one or more requirements. As part of block  114 , any calibration that may be needed may be performed on the product. One or more components may be energized as part of block  114 . 
         [0024]    As described above, a 3D scanning of an incoming part or component may be performed to identify a previously unknown deviation to a baseline sold model or lot-to-lot variations. A vision system may be used to identify a type of electrical connection needed. In some embodiments, the type of electrical connection may be based on the type of data that is to be supported. For example, a printable additive circuit may be used to carry universal serial bus (USB) (2.0 and 3.0), Ethernet (Cat5 and Cat6), Firewire (e.g., IEEE 1394), high-definition multimedia interface (HDMI), coax (e.g., cable communications), RS-232, RS-485, and RS-422 data, or any other type of data. Mechanical mounting, electrical interfacing, weight, and CG parameters may be loaded into a database. The database may be accessed to run an automated (re)design of structures and harnessing to create a new system, function, or design that satisfies one or more requirements with parts or components on hand. The new design may be used to additively grow structural components, overlay harnessing, and interface connectors. In this manner, a manufacturing process may be established that adapts to unknown variations in components while incurring little to no delay in the manufacture of a product. 
         [0025]    In terms of the type of signals that may be transmitted, harnessing may be established or generated to achieve one or more design requirements. For example, in connection with Ethernet communications, a 1 gigabyte (GB) data connection may be provided with the use of standard or conventional connectors. The Ethernet communications may provide for a minimum of seven inches of data transfer, with potentially up to three feet of reliable data transfer. In connection with USB communications, a USB 3.0 connection may be provided with a type B micro plug. The USB communications may provide for a minimum of seven inches of data transfer, with potentially up to three feet of reliable data transfer. In connection with a transfer of power, at least 3 A of current may be transferred at 12V, with potentially 5 A transferred at 12V. The cited values are illustrative and other values may be used in some embodiments. 
         [0026]    Referring to  FIGS. 2A-2E , a sequence of figures is shown in connection with a printing process applied to a dielectric and leads in accordance with one or more embodiments. The sequence may proceed such that a second step or layer builds on top of a first step or layer. The sequence of  FIGS. 2A-2E  may be used to establish a harness or cable. 
         [0027]    In  FIG. 2A , a (close-up view of a) dielectric base layer  202  is shown. The dielectric layer  202  may adhere to one or more materials, such as aluminum. The dielectric material may tend to spread, which may be desirable to impost a smooth surface after printing. 
         [0028]    In  FIG. 2B , silver may be used to print leads  212  and/or connection points  214 . The “squiggly-shaped” leads/lines  212  may represent one design or one-half of a twisted pair. 
         [0029]    In  FIG. 2C , a second layer of dielectric may be applied. The application of the second dielectric layer may generally cover the leads  212 , such that the leads  212  are insulated. Following application of the second dielectric layer, the connection points  214  may still be exposed. 
         [0030]    In  FIG. 2D , silver may be used to print leads  222 . The leads  222  may be substantially similar the leads  212 . The “squiggly-shaped” leads  222  may be one-hundred eighty (180) degrees out of phase with respect to the leads  212 . 
         [0031]    In  FIG. 2E , a third layer of dielectric may be applied. As shown in  FIG. 2E , the leads  222  may be substantially covered by the third dielectric layer. 
         [0032]    As described above, a connector may be grown from a cable or harness to a device. The connector may be designed and fabricated to support a “snap-in” type of connection. The connector may be of a type used to connect “flex pins” to boards. The connector may press into printed pins to create a connection. In some embodiments, a flexible printed connector may be used to connect a printed harness to a short cable with a connector and the board connector for a final connection. 
         [0033]    Referring to  FIGS. 3A-3B , two embodiments are shown for mounting a USB shell connector with an additive cable (e.g., the cable of  FIGS. 2A-2E ). In the first embodiment shown in  FIG. 3A , which may be referred to as a “hard mount,” a USB connector  304  is shown as being applied to a portion of an additive cable  302 . Ink may be used to provide the connection between the cable  302  and the connector  304 . The second embodiment shown in  FIG. 3B  may be similar to the embodiment of  FIG. 3A , except the cable  302  may include a plastic sheet  312  in combination with a metal plat  314 , where the plastic sheet  312  may be used to add flexibility. In this respect, the embodiment of  FIG. 3B  may be referred to as a “flex mount.” 
         [0034]    Referring to  FIG. 4 , a flow chart of a method  400  is shown. The method  400  may be used to manufacture one or more cables or harnesses, potentially on the basis of additive technology. 
         [0035]    In block  402 , (ether) sintering of a cable may be performed to establish connecting pins. Alternatively, a pin drop-in may be used in block  402 . 
         [0036]    In block  404 , the pins may be connected using, e.g., ink printing. Ink printing may be used to create long communication wiring in the cable. 
         [0037]    In block  406 , shielding may be created atop the wiring. Ink printing techniques may be used to create the shielding. 
         [0038]    In block  408 , mechanical protections and interfaces may be created. One or more materials may be used for the mechanical protections and interfaces, such as one or more metals, plastics, etc. 3D printing techniques may be used in block  408 . 
         [0039]    Embodiments of the disclosure may combine aspects of 3D printing, ink jet printing, and laser sintering to accelerate a manufacture of one or more products. As described above, the products may be associated with one or more sectors, such as the commercial sector, the industrial sector, the aerospace sector, or the military sector. An example product is shown in  FIGS. 5A-5B .  FIG. 5A  illustrates a typical sunshade  502  that may be applied to a satellite. The sunshade  502  may include one or more curved surfaces, as reflected via the arrows in  FIG. 5A . It may be desirable in some instances to be able to apply cables around the curved surfaces. 
         [0040]    In  FIG. 5B , the sunshade  502  of  FIG. 5A  is shown with additional components and devices. Those additional components and devices include electronics  504  (e.g., a battery and computing device), USB 3.0 connector hubs  506 , power hubs  508 , Ethernet hubs  510 , and a camera  512 . Also, cables  506   a,    508   a,  and  510   a  may be provided between the hubs  506 ,  508 , and  510 , respectively. The cables  506   a,    508   a,  and  510   a  may be grown or provided in accordance with one or more of the techniques described herein. The particular components and devices shown in  FIGS. 5A-5B  are illustrative; other types of components or devices may be used in some applications. 
         [0041]    In some embodiments various functions or acts may take place at a given location and/or in connection with the operation of one or more apparatuses, systems, or devices. For example, in some embodiments, a portion of a given function or act may be performed at a first device or location, and the remainder of the function or act may be performed at one or more additional devices or locations. 
         [0042]    Embodiments may be implemented using one or more technologies. In some embodiments, an apparatus or system may include one or more processors, and memory storing instructions that, when executed by the one or more processors, cause the apparatus or system to perform one or more methodological acts as described herein. Various mechanical components known to those of skill in the art may be used in some embodiments. 
         [0043]    Embodiments may be implemented as one or more apparatuses, systems, and/or methods. In some embodiments, instructions may be stored on one or more computer-readable media, such as a transitory and/or non-transitory computer-readable medium. The instructions, when executed, may cause an entity (e.g., an apparatus or system) to perform one or more methodological acts as described herein. 
         [0044]    The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. 
         [0045]    While the preferred embodiments to the invention have been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.