Patent Publication Number: US-11642858-B2

Title: Systems, methods, and apparatus for flow media associated with the manufacture of components

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional application of U.S. application Ser. No. 14/812,853, filed Jul. 29, 2015, which is incorporated by reference herein in its entirety for all purposes. 
    
    
     TECHNICAL FIELD 
     This disclosure generally relates to the manufacture and assembly of vehicle components and, more specifically, to controlling a flow of material associated with such vehicle components. 
     BACKGROUND 
     In many instances, carbon fiber may be used to make components by forming components out of a composite laminate which may be made of many different layers of carbon fiber fabric. Moreover, additional materials may be added to the composite laminate to add additional strength and reinforce the composite laminate. However, when such materials are added to the composite laminate, the infusion of materials is limited and may result in the undersaturation or impregnation of some areas of the composite laminate which might not receive enough of the material. Moreover, the infusion of materials might also result in the oversaturation of other areas. Accordingly, such infused components remain limited because they cannot be effectively infused with material. 
     SUMMARY 
     Systems, methods, and apparatus for manufacturing, using, and otherwise controlling a flow of a material through a vehicle component are disclosed herein. Disclosed herein are methods for generating a flow medium associated with a vehicle component. Methods may include determining a first plurality of dimensions and a second plurality of dimensions associated with a flow medium based on one or more flow properties of the vehicle component, the flow medium comprising a plurality of baffle layers and a plurality of spacers. Methods further include generating at least one baffle layer based on the first plurality of dimensions. Methods additionally include generating at least some of the plurality of spacers based on the second plurality of dimensions, the plurality of spacers being positioned on top of the at least one baffle layer. 
     In some embodiments, the first plurality of dimensions and the second plurality of dimensions are determined based on a computational analysis of material flow through the vehicle component. According to some embodiments, the computational analysis identifies at least one convergence in a flow front of a flow of the material through the vehicle component. In various embodiments, the generating of the at least one baffle layer and the generating of the at least some of the plurality of spacers include three dimensional printing of the at least one baffle layer and the at least some of the plurality of spacers. In some embodiments, the at least one baffle layer includes a first baffle layer, and wherein the method further includes generating a second baffle layer on top of the plurality of spacers. 
     According to some embodiments, each baffle layer of the plurality of baffle layers has a contour, and wherein at least one space between at least some of the plurality of baffle layers defines at least one flow path. In various embodiments, the plurality of baffle layers includes a bottom baffle layer and more than one baffle layers arranged on top of the bottom baffle layer. In some embodiments, each baffle layer of the plurality of baffle layers has an edge having a contour defining, at least in part, an area of contact between the baffle layer and the vehicle component, the edge being a leading edge that faces a material source. According to some embodiments, the vehicle component is a component of an aircraft. 
     Also disclosed herein are systems that include one or more processors configured to determine a first plurality of dimensions and a second plurality of dimensions associated with a flow medium based on one or more flow properties of a vehicle component, the flow medium comprising a plurality of baffle layers and a plurality of spacers. The systems also include a three dimensional printer configured to generate at least one baffle layer based on the first plurality of dimensions, and generate at least some of the plurality of spacers based on the second plurality of dimensions, the plurality of spacers being positioned on top of the at least one baffle layer. 
     In some embodiments, the first plurality of dimensions and the second plurality of dimensions are determined based on a computational analysis of material flow through the vehicle component. According to some embodiments, the computational analysis identifies at least one convergence in a flow front of a flow of the material through the vehicle component. In various embodiments, the at least one baffle layer includes a first baffle layer, and further includes generating a second baffle layer on top of the plurality of spacers. In some embodiments, the plurality of baffle layers includes a bottom baffle layer and more than one baffle layers arranged on top of the bottom baffle layer. According to some embodiments, each baffle layer of the plurality of baffle layers has an edge having a contour defining, at least in part, an area of contact between the baffle layer and the vehicle component, the edge being a leading edge that faces a material source. 
     Further disclosed herein are methods for controlling a flow of a material through a vehicle component. The methods include placing vehicle component and a flow medium onto a support member, sealing a vacuum bag around the vehicle component and flow medium, the sealing of the vacuum bag generating a chamber having an airtight seal, the chamber being coupled to a material source and a vacuum pump, and controlling, using one or more flow paths of the flow medium, a flow front of a flow of material through the vehicle component. 
     In some embodiments, the one or more flow paths include a first flow path formed by a first baffle layer and a second baffle layer, the first flow path having at least one flow property determined, at least in part, by a first plurality of spacers positioned between the first baffle layer and the second baffle layer. According to some embodiments, the one or more flow paths further include a second flow path formed by a third baffle layer and a fourth baffle layer, the second flow path having at least one flow property determined, at least in part, by a second plurality of spacers positioned between the third baffle layer and the fourth baffle layer. In various embodiments, the methods further include generating, using the vacuum pump, a first pressure within the chamber, the first pressure being less than an atmospheric pressure, and releasing the material into the chamber, the material being released from the material source. In some embodiments, the material is a resin, and wherein the vehicle component is a preform-laminate. 
     While numerous embodiments have been described to provide an understanding of the presented concepts, the previously described embodiments may be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail so as to not unnecessarily obscure the described concepts. While some concepts have been described in conjunction with the specific examples, it will be understood that these examples are not intended to be limiting, and other suitable examples are contemplated within the embodiments disclosed herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    illustrates a diagram of an example of system for controlling a flow of a material through a vehicle component, implemented in accordance with some embodiments 
         FIG.  2 A  illustrates a diagram of a side view of a flow medium, implemented in accordance with some embodiments. 
         FIG.  2 B  illustrates a diagram of a bottom view of a flow medium, implemented in accordance with some embodiments. 
         FIGS.  3 A- 3 F  illustrate diagrams of an example of a material being infused into a vehicle component, implemented in accordance with some embodiments 
         FIG.  4    illustrates a flow chart of an example of a flow medium generation method, implemented in accordance with some embodiments. 
         FIG.  5    illustrates a flow chart of an example of a component fabrication method, implemented in accordance with some embodiments 
         FIG.  6    illustrates a flow chart of an example of a material infusion method, implemented in accordance with some embodiments. 
         FIG.  7    illustrates a flow chart of an example of an aircraft production and service methodology, implemented in accordance with some embodiments. 
         FIG.  8    illustrates a block diagram of an example of an aircraft, implemented in accordance with some embodiments. 
         FIG.  9    illustrates a data processing system configured in accordance with some embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, numerous specific details are set forth in order to provide a thorough understanding of the presented concepts. The presented concepts may be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail so as to not unnecessarily obscure the described concepts. While some concepts will be described in conjunction with the specific examples, it will be understood that these examples are not intended to be limiting. 
     As discussed above, the infusion of a material, such as resin, into a composite or preform-laminate can provide additional strength to the preform-laminate, thus making the vehicle component that is being manufactured stronger. However, vehicle components may have unique and intricate geometries which cause the flow of material through the component to converge at some locations, and avoid others thus leaving “dry spots” that receive no material. 
     Various embodiments disclosed herein utilize flow media that may be configured to reduce the occurrence of dry spots within a vehicle component that is being infused with a material. The flow media may include several baffle layers and spacers that define flow paths parallel to the flow of material through the vehicle component. The baffle layers and spacers may be configured to facilitate distribution of material to potential dry spots of the composite preform. Accordingly, the features and characteristics of the baffle layers and spacers may be configured to modify or affect flow within the preform of the vehicle component to reduce the occurrence of such dry spots. For example, flow paths included in the flow medium may be configured to increase flow to areas identified as potential “dry spots,” while maintaining or decreasing flow in other areas. In this way, flow media may be configured to ensure that the convergence of flow fronts within the vehicle component is reduced, the occurrence of dry spots is reduced, and the occurrence of oversaturation of portions of the vehicle component is also reduced. 
       FIG.  1    illustrates a diagram of an example of system for controlling a flow of a material through a vehicle component, implemented in accordance with some embodiments. As discussed above, a material, such as a resin, may be provided and infused into a vehicle component which may be a preform-laminate that includes several layers of material, such as carbon fiber. As will be discussed in greater detail below, a vacuum may be used to draw the resin through the vehicle component and fill spaces within the vehicle component to further strengthen it and provide structural reinforcement for the vehicle component. In various embodiments, a system, such as system  100 , may be implemented to control the flow of the material through the vehicle component so that convergences of flow fronts) are reduced and dry spots as well as oversaturation within the vehicle component are reduced. 
     Accordingly, system  100  may include material source  102 . In various embodiments, material source  102  may include a reservoir that may be configured to store an amount of the material to be infused into a preform-vehicle component, such as vehicle component  108 . As discussed above, the material may be a resin or any other suitable material capable of structurally fortifying vehicle component  108 . Moreover, material source  102  may include conduit or tubing configured to couple the reservoir with one or more other components of system  100 , such as vehicle component  108 . In various embodiments, material source  102  may be configured to release the material during a fabrication process and in conjunction with the operation of vacuum pump  106 . Accordingly, material source  102  may release the stored material responsive to a vacuum being applied to material source  102  as well as various other components of system  100  discussed in greater detail below. 
     System  100  may further include tool or mandrel-support member  104  which may be configured to provide a support platform for vehicle component  108  during infusion operations. Accordingly, tool or mandrel-support member  104  may have a shape or geometry configured to match a surface of vehicle component  108  such that vehicle component  108  is mechanically coupled to tool or mandrel-support member  104  during infusion operations, and is held in place. In various embodiments, tool or mandrel-support member  104  may be made of a material, such as a metal or polymer, which is impermeable to the material stored in material source  102 . 
     As discussed above, system  100  may also include vacuum pump  106  which may be configured to generate a vacuum having a negative pressure relative to material source  102 . As shown in  FIG.  1   , vacuum pump  106  is coupled to material source  102  via vehicle component  108  and flow medium  114 . Accordingly, the vacuum generated by vacuum pump  106  may cause material included in material source  102  to leave material source  102  and proceed into vehicle component  108  and flow medium  114 . In some embodiments, vacuum pump  106  includes a reservoir configured to collect excess material that has passed through vehicle component  108  and/or flow medium  114 . 
     As previously stated, system  100  is coupled to or configured to include vehicle component  108 . In some embodiments, vehicle component  108  may be a component of an aircraft or a spacecraft. For example, vehicle component  108  may be a rib of an airplane wing, or a top surface or a bottom surface of the airplane wing. Accordingly, vehicle component  108  may be configured to include a material having a high strength to weight ratio. For example, vehicle component  108  may be a preform-laminate made of several layers of carbon fiber fabric. In various embodiments, vehicle component  108  may be a component of a boat or other maritime vessel, or an automobile. 
     In various embodiments, system  100  further includes vacuum bag-film  112  which may be an impermeable layer configured to seal the components of system  100  included between vacuum pump  106  and material source  102 , thus sealing the vacuum generated by vacuum pump  106  and the flow of material from material source  102 . In some embodiments, film  112  is placed on top of flow medium  114  and vehicle component  108  after flow medium  114  and vehicle component  108  have been included in system  100 . In various embodiments, film  112  is made of a material that is impermeable to the material stored in material source  102 . In various embodiments, film  112  may be configured to have an airtight seal with material source  102  and vacuum pump  106 . Moreover, tool or mandrel-support member  104  may also have an airtight seal with material source  102  and vacuum pump  106 . 
     System  100  may also include flow medium  114 . As will be discussed in greater detail below, flow medium  114  may be configured to provide one or more parallel flow paths to vehicle component  108 . Each flow path provided by flow medium  114  may be configured to increase or decrease local flow in vehicle component  108  at a location adjacent to the interface, such as interface  131 , between the flow path and vehicle component  108 . In this way, flow medium  114  may be configured to modify and control the flow of material through vehicle component  108  at multiple different locations across vehicle component  108  as the material proceeds through vehicle component  108  during infusion operations. As will be discussed in greater detail below, flow medium  114  may include various structural members that are configured to define the shape of each flow path, as well as each flow path&#39;s flow properties. As used herein, a flow property may include a flow resistance and/or a vacuum strength which may be inversely proportional to each other. As will be discussed in greater detail below, a flow property may be a property of a flow path provided by flow medium  114  or a flow path provided by vehicle component  108 . In some embodiments, porous release material  127  may be included between flow medium  114  and vehicle component  108 . Accordingly, porous release material  127  may be configured to be porous to the material, which may be a resin, and may thus be configured to enable material and vacuum flow while also being configured to prevent flow medium  114  from bonding to vehicle component  108 . In some embodiments, porous release material  127  may include a perforated polytetrafluoroethylene (PTFE) coated fiberglass fabric, or a perforated thin plastic sheet. 
     Accordingly, flow medium  114  may include several structural members, such as baffle layers and spacers. For example, flow medium  114  may include first baffle layer  116 , second baffle layer  118 , third baffle layer  120 , fourth baffle layer  122 , fifth baffle layer  124 , and sixth baffle layer  126  which may also be configured to be a bottom surface of flow medium  114 , as will be discussed in greater detail below. In various embodiments, a baffle layer may be made of a material, such as a metal or polymer, which is impermeable to the material stored in material source  102 . For example, a baffle layer may be made of aluminum or any other suitable material impermeable to various resins used during infusion operations. Accordingly, a chamber or internal volume between baffle layers may form a flow path and may be coupled to vehicle component  108  via an interface or point of contact between flow medium  114  and vehicle component  108 . The internal volume may also be coupled to vacuum pump  106 . In this way, a flow path may be formed between vacuum pump  106  and vehicle component  108  via internal volumes defined by baffle layers. 
     For example, first flow path  132  may be defined by first baffle layer  116  and second baffle layer  118 . Moreover, second flow path  134  may be formed between second baffle layer  118  and third baffle layer  120 . Furthermore, third flow path  136  may be formed between third baffle layer  120  and fourth baffle layer  122 . In this way, the different baffle layers may be configured to form several independent flow paths each having flow properties specifically configured to promote uniform flow throughout vehicle component  108 , and reduce the occurrence of dry spots. 
     Flow medium  114  may also include various spacers, such as spacer  128  which may be separated from other spacers by an internal volume, such as internal volume  130 . In various embodiments, the spacers may be positioned within internal volumes of flow paths defined by the baffle layers, and may thus affect the flow of material through such flow paths. Accordingly, various dimensions of the spacers, such as height and width may be configured to achieve a particular flow property of the flow path that includes the spacers. Moreover, geometries of the spacers, which may refer to their cross-sectional shape and hydrodynamic properties or shaping features, may also be configured to achieve a particular flow property. For example, spacers may have larger physical dimensions, such as larger diameters, in flow paths that have interfaces adjacent to portions of vehicle component  108  through which flow of the material is to be reduced or slowed. In another example, the spacers may have smaller physical dimensions in flow paths that have interfaces adjacent to portions of vehicle component  108  through which flow of the material is to be increased or facilitated. In this way, features of the spacers may configure, at least in part, an internal flow resistance of the flow path that includes the spacers as well as a strength of a vacuum applied to the interface of the flow path and vehicle component  108 , and thus configure a localized effect of flow medium  114  on vehicle component  108 . 
     In some embodiments, the flow property determined by the spacers and corresponding flow path, such as flow path  132 , may be inversely proportional to a flow property of vehicle component  108  in a region adjacent to an interface, such as interface  131 , between flow path  132  and vehicle component  108 . For example, the portion of vehicle component  108  adjacent to interface  131  may be a dry spot, or area that has one or flow properties making it prone to undersaturation. Such a flow property may be equivalent to a relatively high flow resistance. In some embodiments, flow path  132 , as well as spacers within flow path  132 , may be configured to have a flow property and equivalent flow resistance that is relatively low and is inversely proportional to the flow property of the portion of vehicle component  108  that is adjacent to interface  131 . 
     As will be discussed in greater detail below, different flow paths defined by different portions of flow medium  114  may be configured to have different flow properties. Moreover, the different flow paths may be configured to counteract flow properties of vehicle component  108  that may otherwise cause flow front convergences and dry spots within vehicle component  108 . In this way, each flow path defined within flow medium  114  may be specifically configured based on flow properties of vehicle component  108 , and may collectively reduce the occurrence of dry spots within vehicle component  108  during infusion operations. 
       FIG.  2 A  illustrates a diagram of a side view of a flow medium, implemented in accordance with some embodiments. As discussed above, flow medium  114  may include structural members that are configured to define several different internal volumes that provide additional flow paths for a material, such as resin, which may be infused into vehicle component  108 . For example, flow medium  114  may include first baffle layer  116 , second baffle layer  118 , third baffle layer  120 , fourth baffle layer  122 , fifth baffle layer  124 , and sixth baffle layer  126  which may also be configured to be a bottom surface of flow medium  114 . As discussed in greater detail below, sixth baffle layer  126  may also include various features, such as holes, that are configured to provide additional permeability to one or more flow paths included within flow medium  114 . 
     As was previously discussed, structural members, such as spacers, included in the flow paths may be configured to determine flow properties of the flow paths as well as flow properties of portions of vehicle component  108 . As will be discussed in greater detail below with reference to  FIG.  2 B , a shape or contour of an edge of one or more baffle layers, such as edge  202 , may be specifically configured to further affect flow properties of one or more portions of vehicle component  108 . 
       FIG.  2 B  illustrates a diagram of a bottom view of a flow medium, implemented in accordance with some embodiments. As shown in  FIG.  2 B , flow medium  114  has a geometry that is configured to parallel or match a surface geometry of vehicle component  108 . In one example, vehicle component  108  is a rib of an airplane wing. Accordingly, flow medium  114  is configured to have a shape that matches a surface of a rib of an airplane wing. In some embodiments, peripheral edges of flow medium  114 , such as peripheral edge  204 , may be sealed to seal edges of flow paths included within flow medium  114 . As discussed above, flow medium  114  may include first baffle layer  116 , second baffle layer  118 , third baffle layer  120 , fourth baffle layer  122 , fifth baffle layer  124 , and sixth baffle layer  126 . 
     As shown in  FIGS.  2 A and  2 B , each of baffle layers  116 ,  118 ,  120 ,  122 ,  124 , and  126  may be configured to have edges  202 ,  206 ,  208 ,  210 ,  212 , and  214  that have particular contours or geometries. In various embodiments, an edge of a baffle layer, such as baffle layer  116 , defines an interface, such as interface  131 , between the baffle layer  116  and vehicle component  108 . Accordingly, a contour  216  of an edge, such as edge  206 , defines, at least in part, an interface  131  of vehicle component  108  with which the flow path  132  associated with the baffle layers  116  and  118  interacts.  FIG.  2 B  illustrates an example in which contours  216 ,  218 ,  220 ,  222 , and  224  of the edges  206 ,  208 ,  210 ,  212 , and  214  of the baffle layers  116 ,  118 ,  120 ,  122 ,  124 , and  126  are configured to provide several staggered, unimpeded flow paths  132 ,  134 ,  136 ,  304 , and  306 , discussed in greater detail below with reference to  FIGS.  3 A- 3 F , which are configured based on a previously determined geometry of a dry spot of vehicle component  108 . In this example, contours of the baffle layers  116 ,  118 ,  120 ,  122 ,  124 , and  126  have been configured such that at portion  226 , flow medium  114  is bounded by the top baffle layer, which is first baffle layer  116 . Accordingly, all other flow paths  132 ,  134 ,  136 ,  304 , and  306  are open and unimpeded paths. Accordingly, the contours of the leading edges  202 ,  206 ,  208 ,  210 ,  212 , and  214  associated with flow paths  132 ,  134 ,  136 ,  304 , and  306  have been configured to provide less flow resistance between vehicle component  108  and vacuum pump  106 , thus increasing the overall flow through vehicle component  108  at portion  226 . Further along the airplane rib as the dry spot terminates, the edges  202 ,  206 ,  208 ,  210 ,  212 , and  214  associated with flow paths  132 ,  134 ,  136 ,  304 , and  306  contact vehicle component  108 , and separate flow paths  132 ,  134 ,  136 ,  304 , and  306  are established that each have specific flow properties. In this way, open areas, such as portion  226 , of flow paths  132 ,  134 ,  136 ,  304 , and  306  as well as their dimensions may be configured to have little flow resistance, stronger vacuum strength, and promote flow within vehicle component  108 . As discussed above, in various embodiments, porous release material  127  may be positioned between flow medium  114  and vehicle component  108 . Accordingly, contact between edges  202 ,  206 ,  208 ,  210 ,  212 , and  214  and vehicle component  108  may occur via porous release material  127 . 
       FIGS.  3 A- 3 F  illustrate diagrams of an example of a material being infused into a vehicle component, implemented in accordance with some embodiments. As previously discussed, system  100  may be implemented to infuse a material, such as resin, into a vehicle component. As shown in  FIG.  3 A , material may be provided from material source  102  and may progress through vehicle component  108  in accordance with the negative pressure gradient generated by vacuum pump  106 . Accordingly, leading edge  302  of the volume of material may progress through vehicle component  108  based on flow properties of flow paths, such as flow paths  132 ,  134 ,  136 ,  304 , and  306 , established by vehicle component  108  as well as flow medium  114 . As will be discussed in greater detail below with reference to  FIGS.  3 B- 3 F , as leading edge  302  progresses through vehicle component  108 , the material contacts different interfaces, such as interface  131 , of different flow paths  132 ,  134 ,  136 ,  304 , and  306  that may each have their own respective flow properties configured to increase or reduce flow within vehicle component  108  at each respective interface. 
       FIG.  3 B  illustrates material being infused into vehicle component  108  after an amount of time has elapsed, and leading edge  302  has progressed further through vehicle component  108 . As shown in  FIG.  3 B , the material has contacted interface  131  associated with first flow path  132  which is defined by first baffle layer  116  and second baffle layer  118 . Accordingly, an amount of the material has begun flowing through first flow path  132 . Furthermore, the material also continues to progress through vehicle component  108 . Accordingly, leading edge  302  continues to progress through vehicle component  108  and towards vacuum pump  106 . As previously discussed, an amount of material and a rate of flow of the material that progresses through first flow path  132  may be determined based on structural members included in first flow path  132 , which may be spacers. Accordingly, structural characteristics of first flow path  132  may determine the amount of material wicked away from vehicle component  108  and into flow medium  114 . As discussed above, the less flow resistance that first flow path  132  has, the more material is wicked away, and the more localized flow occurs within vehicle component  108  at the interface of first flow path  132  and vehicle component  108 . 
       FIG.  3 C  further illustrates material being infused into vehicle component  108  after an additional amount of time has elapsed. As shown in  FIG.  3 C , leading edge  302  has continued to progress through vehicle component  108 . The material has also contacted second flow path  134  which is defined by second baffle layer  118  and third baffle layer  120 . Accordingly, an amount of the material has begun flowing through second flow path  134 . As previously discussed, structural features or characteristics of second flow path  134  may determine a rate of flow of material through second flow path  134 . Moreover, second flow path  134  may be configured to have different flow characteristics than first flow path  132 , and may have a different effect on local flow within vehicle component  108  at interface  310  of second flow path  134  and vehicle component  108 . In this way, different flow paths may be configured differently to increase or decrease local flow of the material along a length of vehicle component  108 . Moreover, structural features or characteristics of a flow path may also be varied along a width of vehicle component  108  to provide additional configurability of the flow within vehicle component  108 . As will be discussed in greater detail below, in some embodiments, the structural features or characteristics, which may include spacers, may be varied in a concentric fashion starting from an edge, such as edge  206 , of a baffle layer, such as baffle layer  118 . Thus, as will be discussed in greater detail below, variations in the structural features or characteristics may maintain a shape or pattern determined by a contour, such as contour  216 , and may be varied along a length of vehicle component  108 .  FIG.  3 D  further illustrates material being infused into vehicle component  108  after an additional amount of time has elapsed. As shown in  FIG.  3 D , leading edge  302  has continued to progress through vehicle component  108 . The material has also contacted third flow path  136  which is defined by third baffle layer  120  and fourth baffle layer  122 . Accordingly, an amount of the material has begun flowing through third flow path  136 . As previously discussed, structural features or characteristics of third flow path  136  may determine a rate of flow of material through third flow path  136 . As similarly discussed above, features of third flow path  136 , such as a size, shape, and density of spacers, may be configured to configure or determine a flow resistance of third flow path  136 , and such flow properties may be different than those of first flow path  132  and second flow path  134 . In this way, each flow path may be specifically configured to control the flow of material through vehicle component  108 . 
       FIG.  3 E  further illustrates material being infused into vehicle component  108  after an additional amount of time has elapsed. As shown in  FIG.  3 E , leading edge  302  has continued to progress through vehicle component  108 . The material has also contacted fourth flow path  304  which is defined by fourth baffle layer  122  and fifth baffle layer  124 . Accordingly, an amount of the material has begun flowing through fourth flow path  304 . As previously discussed, structural features or characteristics of fourth flow path  304  may determine a rate of flow of material through fourth flow path  304 . Accordingly, material may continue to flow through first flow path  132 , second flow path  134 , third flow path  136 , vehicle component  108  and now fourth flow path  304 . 
       FIG.  3 F  further illustrates material being infused into vehicle component  108  after an additional amount of time has elapsed. As shown in  FIG.  3 F , leading edge  302  has continued to progress through vehicle component  108 . The material has also contacted fifth flow path  306  which is defined by fifth baffle layer  124  and sixth baffle layer  126 . Accordingly, an amount of the material has begun flowing through fifth flow path  306 . As previously discussed, structural features or characteristics of fifth flow path  306  may determine a rate of flow of material through fifth flow path  306 . In this way, numerous additional flow paths  132 ,  134 ,  136 ,  304 , and  306  may be provided in parallel to flow path  312  of vehicle component  108 . However, properties of flow paths  132 ,  134 ,  136 ,  304 , and  306 , such as flow resistance, may be configured to increase flow in some areas and decrease flow in others. Accordingly, the configuration of structural members and contours of different flow paths  132 ,  134 ,  136 ,  304 , and  306  may provide specific or selective adjustments to flow through vehicle component  108  along a length of vehicle component  108  while the configuration of structural members across a width of flow paths  132 ,  134 ,  136 ,  304 , and  306  may provide specific adjustments along a width of vehicle component  108 . 
       FIG.  4    illustrates a flow chart of an example of a flow medium generation method, implemented in accordance with some embodiments. As previously stated, various dimensions and features of a flow medium, such as flow medium  114 , may be determined and configured based on flow characteristics and properties of the vehicle component, such as vehicle component  108 , associated with flow medium  114 . Accordingly, a flow medium generation method, such as method  400 , may be implemented to determine the flow characteristics and properties of the vehicle component, and manufacture a flow medium that has features and dimensions that are configured based on the determined flow characteristics and properties. 
     Accordingly, method  400  may commence with operation  402  during which a first plurality of dimensions and a second plurality of dimensions associated with flow medium  114  may be determined based on one or more flow properties of vehicle component  108 . As previously discussed, flow medium  114  includes a plurality of baffle layers and a plurality of spacers. Accordingly, the first dimensions may identify physical parameters and dimensions of the baffle layers. Moreover, the second dimensions may identify physical parameters and dimensions of the spacers. As similarly discussed above, such dimensions may be determined based on flow properties of vehicle component  108  which may identify one or more problem areas which may be areas where a flow front converges. As discussed above, the geometry and shape of vehicle component  108  may cause flow within vehicle component  108  to not be uniform. As a result, the flow of material through vehicle component  108 , unaided by flow medium  114 , might not be uniform, and might leave dry spots within vehicle component  108   
     In various embodiments, the flow properties of vehicle component  108  may be determined based on computational fluid dynamics analysis. Accordingly, a data processing system, such as data processing system  900  discussed in greater detail below with reference to  FIG.  9   , may be implemented to model and analyze the flow of a material, such as resin, through vehicle component  108 , which may be made of a preform-laminate material such as carbon fiber. In various embodiments, the computational fluid dynamics analysis may identify at least one convergence in a flow front of a flow of the material through the vehicle component. Accordingly, the computational fluid dynamics analysis may identify dry spots, or areas having flow of less than a threshold value, and may generate a representation of a spatial distribution of the modeled flow that may form the basis for determining the first dimensions and second dimensions. In various embodiments, the data processing system may be further configured to determine the first dimensions and the second dimensions based on the generated representation of modeled flow. 
     In some embodiments, the computational fluid dynamics analysis may generate a fill-time heat map that identifies and characterizes individual fill-time values that may be stored in a data structure, such as a data table. For example, the data table may include rows and columns of data fields corresponding to a spatial representation of vehicle component  108 . In this way, data fields of the data structure may represent pixels of a spatial representation that correspond to physical locations of vehicle component  108 . The values may characterize or represent flow rates and/or fill times associated with areas of vehicle component  108 . In various embodiments, boundaries may be identified based on the values included in the heat map. In some embodiments, one or more designated values may be used to determine the boundaries. In one example, a first designated value of 10 minutes may be used to identify a first boundary and a second designated value of 20 minutes may be used to identify a second boundary. Additional designated values may be implemented for 30 minutes, 40 minutes, or any other suitable unit and/or gradation of time or flow rate. More specifically, areas of vehicle component  108  having common or similar values may be associated or connected with each other to form distinct lines that may be boundaries. For example, a first boundary may be formed based on areas that have a fill-time value of 10 minutes. In this way, several boundaries may be identified, and may form the basis for determining contours  216 ,  218 ,  220 ,  222 , and  224  of edges  206 ,  208 ,  210 ,  212 , and  214 . In various embodiments, each boundary may be separated by a distance that is directly proportional to the gradation of time units used for the designated values. 
     In various embodiments, the first dimensions and second dimensions may be determined based, at least in part, on the fill-time values and boundaries discussed above. For example, the first dimensions, which may include dimensions of contours  216 ,  218 ,  220 ,  222 , and  224  of edges  206 ,  208 ,  210 ,  212 , and  214 , may be determined based on their associated boundaries and may have a similar shape as their associated boundaries. Moreover, a number of baffle layers may be determined by dividing a time difference by a designated value to generate space divisions. For example, if a gradation of 10 minutes, 20 minutes, 30 minutes, and 40 minutes is used, the time difference may be 10 minutes. In some embodiments, the designated value may be 2. Accordingly, baffle layers may be generated for every 5 minute increment in fill-time values. In this way, the fill-time differences may be utilized to characterize spatial divisions among baffle layers and determine dimensions of the baffle layers. In some embodiments, a physical distance between boundaries may be divided by a designated number to characterize spatial divisions among baffle layers and determine dimensions of the baffle layers based. In this way, spatial differences between boundaries may be utilized. 
     In various embodiments, the second dimensions may be determined based, at least in part on the first dimensions. As discussed above, baffle layers, such as baffle layers  116 ,  118 ,  120 ,  122 ,  124 , and  126 , may be configured to form various flow paths in which spacers may be positioned. As also discussed above, the spacers included in a particular flow path may vary in size and shape. In some embodiments, the spacers may be configured to have dimensions that vary uniformly and progressively along a flow path. Accordingly, the spacers may have an initial set of dimensions at the beginning of the flow path and adjacent to a contour. Such an initial set of dimensions may be a default value, or may have been previously determined by an engineer. The initial dimensions of the spacers may be configured to be open and provide relatively little flow resistance. Accordingly, the initial dimensions may be smaller, have a shape that provides little hydrodynamic resistance, and/or may have a lower density per unit of area of baffle layer. The dimensions of the spacers may be varied in a linear or non-linear fashion along the length of the flow path and in a manner that is concentric with a shape or curvature of their associated contour. More specifically a size, density, and/or shape of the spacers may be individually varied, or varied in combination. Accordingly, the dimensions may be varied to provide more flow resistance, and have dimensions that are larger, have a shape that provides more hydrodynamic resistance, and/or has a higher density. In some embodiments, the dimensions may be varied to the extent that they choke off resin flow through the flow path and thus reduce resin waste incurred by an infusion method. As similarly discussed above, dimensions may be varied from a beginning of a flow path, such as flow path  132  which may be adjacent to material source  102 , to an end of the flow path which may be adjacent to vacuum pump  106 . 
     Method  400  may proceed to operation  404  during which at least one baffle layer may be generated based on the first plurality of dimensions. In various embodiments, the at least one baffle layer may be generated using a three dimensional (3D) printing process. Accordingly, the first dimensions may be provided to a 3D printer, and the 3D printer may fabricate the at least one baffle layer as part of an automated manufacturing process. In some embodiments, baffle layers may be tooled from a material such as metal. In various embodiments, the use of a material such as metal may enable the use of reusable flow media that may be cleaned of resin after one use, and then used again in another as will be discussed in greater detail below with reference to  FIG.  5   . In some embodiments, baffle layers may be generated utilizing direct metal laser sintering (DMLS). 
     Method  400  may proceed to operation  406  during which the plurality of spacers may be generated based on the second plurality of dimensions. In various embodiments, the spacers may also be generated using a 3D printing process. As similarly discussed above, the second dimensions may be provided to a 3D printer, and the 3D printer may fabricate one or more of the spacers as part of the automated manufacturing process. Moreover, as similarly discussed above, the spacers may be tooled from a material such as metal or may be generated using DMLS. As previously discussed, various parameters or dimensions of the spacers may affect the flow properties and performance of associated flow paths which may include flow paths  132 ,  134 ,  136 ,  304 , and  306 . For example, spacers that are larger and or placed closer together may provide increased flow resistance in a flow path. Moreover, a shorter height of spacers as well as their associated flow path may also provide an increased flow resistance relative to taller spacers and taller flow paths. The opposite may be true for spacers that are smaller and/or placed farther apart as well as spacers and flow paths that are taller. 
     Method  400  may proceed to operation  408  during which the at least some of the plurality of spacers may be joined with the at least one baffle layer. In some embodiments, if a 3D printing process is implemented, the joining during operation  408  may be part of the same printing process implemented for the spacers. Accordingly, the spacers may be printed directly on the baffle layer, and may be joined with the baffle layer via their concurrent generation during the same printing process. In various embodiments, where a metal material is used, the spacers may be soldered or welded to the baffle layers. In various embodiments, the spacers as well as the baffle layers may be created using DMLS. Accordingly, operations  404 ,  406 , and  408  may be implemented as part of one manufacturing or fabrication operation that utilizes DMLS to form a contiguous structure, such as flow medium  114 , that includes the at least one baffle layer and the spacers. 
     Method  400  may proceed to operation  410  during which it may be determined whether or not additional baffle layers and/or spacers should be generated. In various embodiments, such a determination may be made based on the dimensions determined during operation  402  which may be stored in a computer assisted design (CAD) model. For example, if a first baffle layer has been generated, but a second and third baffle layer still remain, it may be determined that additional baffle layers should be generated. If it is determined that additional baffle layers and/or spacers should be generated, method  400  may return to operation  404 . If it is determined that additional baffle layers and/or spacers should not be generated, method  400  may terminate. 
       FIG.  5    illustrates a flow chart of an example of a component fabrication method, implemented in accordance with some embodiments. As discussed above, the controlling of flow of a material through a vehicle component, such as vehicle component  108 , may be part of a manufacturing and assembly process. Accordingly, method  500  may be implemented to facilitate the manufacture of vehicle component  108  as well as other vehicle components. 
     Accordingly, method  500  may commence with operation  502  during which flow properties of vehicle component  108  may be analyzed. As discussed above, a computational fluid dynamics analysis may be implemented to identify convergences of flow fronts within vehicle component  108 . Moreover, the computational fluid dynamics analysis and/or an analysis performed by an assembly worker may be implemented to identify dimensions and features of a flow medium, such as flow medium  114 , based on the identified convergences. Accordingly, the number of baffle layers, shape of the baffle layers, number of spacers, dimensions of spacers, and density of spacers may all be configured based on the computational fluid dynamics analysis, and may be specific to the flow properties of vehicle component  108 . 
     Method  500  may proceed to operation  504  during which flow medium  114  may be generated based on the analyzed properties. Accordingly, based on the determined dimensions, flow medium  114  may be generated by a manufacturing process, such as a 3D printing process. As similarly discussed above, other manufacturing processes may be implemented as well, such as a tooling process. In this way, flow medium  114  may be manufactured or generated using various different materials ranging from metals to polymers. 
     Method  500  may proceed to operation  506  during which an infusion system may be assembled. As discussed above, the system may include flow medium  114 . Accordingly, during operation  506 , vehicle component  108  and flow medium  114  may be placed within system  100  and may be sealed by film  112 . In various embodiments, the assembly may be performed by the assembly worker. In some embodiments, the assembly may be performed by an assembly robot as part of an automated process. 
     Method  500  may proceed to operation  508  during which a negative pressure gradient may be generated by vacuum pump  106 . As previously discussed, vacuum pump  106  may be activated and generate a vacuum within the sealed portion of system  100 . Accordingly, a negative pressure gradient may be generated across vehicle component  108  and flow medium  114 , and may facilitate the movement of a material, such as resin, from material source  102  into vehicle component  108 . 
     Method  500  may proceed to operation  510  during which a material may be infused into vehicle component  108 . As previously discussed with reference to  FIGS.  3 A- 3 F , as the negative pressure gradient continues to be applied to vehicle component  108  and flow medium  114 , the material is pulled along various flow paths in accordance with the flow properties of vehicle component  108  as well as flow properties of flow medium  114 . As previously discussed, during the infusion, the progression of material through vehicle component  108  may be controlled such that the convergence of flow fronts is reduced. In this way, the modification of flow provided by flow medium  114  ensures that the incidence of the dry spots that were identified during operation  502  is reduced. 
     Method  500  may proceed to operation  511  during which heat may be applied to infused vehicle component  108 . In various embodiments, the application of heat to infused vehicle component  108  solidifies and cures the material that has been infused. Accordingly, one the application of heat has been completed, the material provides vehicle component with increase structural support and reinforcement. In this way, infused vehicle component  108  may be structurally reinforced by the infusion of a material, such as resin. Moreover, because the infusion was implemented using flow medium  114 , the incidence of dry spots has been reduced, and the strength of vehicle component  108  has been increased. 
     Method  500  may proceed to operation  512  during which the flow medium may be removed from the vehicle component. Accordingly, a system, such as system  100 , may be disassembled such that flow medium  114  may be removed from system  100  after the curing process. Accordingly, once the infusion of vehicle component  108  has been completed, flow medium  114  may be removed and vehicle component  108  may have a substantially markoff-free upper surface. 
     Method  500  may proceed to operation  514  during which it may be determined whether or not additional vehicle components should be infused. Such a determination may be made based on parameters of a broader manufacturing process in which method  500  may be implemented. For example, if there are numerous similar parts or components to be manufactured for a single vehicle, or if there are numerous vehicles to be manufactured, it may be determined that additional components should be infused. If it is determined that additional vehicle components should be infused, method  500  may proceed to operation  516  during which material may be removed from flow medium  114 . For example, if flow medium  114  is made of metal, flow medium  114  may be placed in an incinerator and any residual material that remains in flow medium  114  may be burned away. If flow medium  114  is made of a polymer via a 3D printing process, operation  516  might not be performed, and method  500  may return to operation  504 . If it is determined that no additional vehicle components should be infused, method  500  may terminate. 
       FIG.  6    illustrates a flow chart of an example of a material infusion method, implemented in accordance with some embodiments. As discussed above, system  100  may be used to infuse a material into vehicle component  108 . In some embodiments, a material infusion method, such as method  600 , may be implemented using system  100 . Accordingly, method  600  may commence with operation  602  during which a vehicle component and a flow medium may be placed onto a support member. As previously discussed, a vehicle component, such as vehicle component  108  may be positioned on tool or mandrel-support member  104 , and a flow medium, such as flow medium  114  may be placed on top of vehicle component  108 . As discussed above, flow medium  114  may include various baffle layers  116 ,  118 ,  120 ,  122 ,  124 , and  126  and spacers, such as spacer  128 , that may be configured based on flow properties of vehicle component  108 . 
     Method  600  may proceed to operation  604  during which a vacuum bag may be sealed around the vehicle component and the flow medium. In various embodiments, the sealing of the vacuum bag generates a chamber having an airtight seal. In various embodiments, the vacuum bag may be a bagging film, such as film  112 . Accordingly, film  112  may be placed over flow medium  114 , and peripheral edges of film  112  may be sealed such that the surface of film  112  facing flow medium  114  forms a boundary of the airtight chamber. In various embodiments, the airtight chamber formed by film  112  may be configured such that material source  102  and vacuum pump  106  may be coupled with and may interact with flow medium  114  and vehicle component  108  without degrading the airtight seal. 
     Method  600  may proceed to operation  606  during which a first pressure may be generated within the chamber. Accordingly, vacuum pump  106  may be activated and may generate a first pressure, which may be a relative vacuum, within the airtight chamber formed by film  112 . As disclosed herein, the first pressure or vacuum generated by vacuum pump  106  may refer to a pressure that is less than an atmospheric pressure, and may be less than a pressure within material source  102 . Accordingly, the vacuum may be generated and applied at one end of flow medium  114  and vehicle component  108 , and may generate vacuums within flow paths of flow medium  114  and vehicle component  108 , such as flow paths  132 ,  134 ,  136 ,  304 , and  306 . 
     Method  600  may proceed to operation  608  during which a material may be released from a material source into the chamber. Accordingly, material source  102  may release the material that is to be infused into vehicle component  108 . As previously discussed, the material may be a resin that may be used to fortify preform-laminates. Once released from material source  102 , the vacuum generated by vacuum pump  106  may pull the resin through vehicle component  108  and through various flow paths, such as flow paths  132 ,  134 ,  136 ,  304 , and  306 , as similarly discussed above with reference to  FIGS.  3 A- 3 F . 
     Method  600  may proceed to operation  610  during which a flow front of a flow of material through vehicle component  108  may be controlled. In various embodiments, the flow front may be controlled using one or more flow paths of flow medium  114 . Accordingly, as the material is pulled through vehicle component  108 , a flow front or leading edge  302  may contact and interact with different flow paths  132 ,  134 ,  136 ,  304 , and  306 . As discussed above, each of the flow paths may have flow properties, such as a flow resistance, which may be configured to influence local flow at interfaces associated with flow paths  132 ,  134 ,  136 ,  304 , and  306 . Accordingly, as leading edge  302  progresses through vehicle component  108 , flow properties of flow paths  132 ,  134 ,  136 ,  304 , and  306  may selectively modify flow along the flow front represented by leading edge  302  such that the flow front does not converge at some areas and leave dry spots or undersaturated spots at others. In this way, flow medium  114  may control a flow of material throughout the entirety of vehicle component  108  and ensure that undersaturation and oversaturation of different portions of vehicle component  108  is reduced. 
     Embodiments of the disclosure may be implemented in combination with an aircraft manufacturing and service method  700  as shown in  FIG.  7    and an aircraft  702  as shown in  FIG.  8   . During pre-production, illustrative service method  700  may include specification and design  704  of the aircraft  702  and material procurement  706 . During production, component and subassembly manufacturing  708  and system integration  710  of the aircraft  702  takes place. Thereafter, the aircraft  702  may go through certification and delivery  712  in order to be placed in service  714 . While in service by a customer, the aircraft  702  is scheduled for routine maintenance and service  716  (which may also include modification, reconfiguration, refurbishment, and so on). Accordingly flow medium  114  may be implemented in conjunction with operations such as component and subassembly manufacturing  708  and system integration  710 , and components of assemblies such as airframe  178  and interior  722  discussed in greater detail below. 
     Each of the processes of service method  700  may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of venders, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on. 
     As shown in  FIG.  8   , the aircraft  702  produced by illustrative method  700  may include an airframe  718  with a plurality of systems  720  and an interior  722 . Examples of high-level systems  720  include one or more of a propulsion system  724 , an electrical system  726 , a hydraulic system  728 , and an environmental system  730 . Any number of other systems may be included. Although an aerospace example is shown, the principles of the invention may be applied to other industries, such as the automotive industry. 
     Apparatus and methods embodied herein may be employed during any one or more of the stages of the production and service method  700 . For example, components or subassemblies corresponding to production operation  708  may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft  702  is in service. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the production operations  708  and  710 , for example, by substantially expediting assembly of or reducing the cost of an aircraft  702 . Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft  702  is in service, for example and without limitation, to maintenance and service  716 . 
       FIG.  9    illustrates a data processing system configured in accordance with some embodiments. Data processing system  900 , also referred to herein as a computer system, may be used to implement one or more computers or processing devices used in a controller, server, or other components of systems described above. In some embodiments, data processing system  900  includes communications framework  902 , which provides communications between processor unit  904 , memory  906 , persistent storage  908 , communications unit  910 , input/output (I/O) unit  912 , and display  914 . In this example, communications framework  902  may take the form of a bus system. 
     Processor unit  904  serves to execute instructions for software that may be loaded into memory  906 . Processor unit  904  may be a number of processors, as may be included in a multi-processor core. In various embodiments, processor unit  904  is specifically configured to process large amounts of data that may be involved when generating and utilizing computational flow models, as discussed above. Thus, processor unit  904  may be an application specific processor that may be implemented as one or more application specific integrated circuits (ASICs) within a processing system. Such specific configuration of processor unit  904  may provide increased efficiency when processing the large amounts of data involved with the previously described systems, devices, and methods. Moreover, in some embodiments, processor unit  904  may include one or more reprogrammable logic devices, such as field-programmable gate arrays (FPGAs), that may be programmed or specifically configured to optimally perform the previously described processing operations in the context of large and complex data sets associated with computational modeling of material flow through a vehicle component. 
     Memory  906  and persistent storage  908  are examples of storage devices  916 . A storage device is any piece of hardware that is capable of storing information, such as, for example, without limitation, data, program code in functional form, and/or other suitable information either on a temporary basis and/or a permanent basis. Storage devices  916  may also be referred to as computer readable storage devices in these illustrative examples. Memory  906 , in these examples, may be, for example, a random access memory or any other suitable volatile or non-volatile storage device. Persistent storage  908  may take various forms, depending on the particular implementation. For example, persistent storage  908  may contain one or more components or devices. For example, persistent storage  908  may be a hard drive, a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The media used by persistent storage  908  also may be removable. For example, a removable hard drive may be used for persistent storage  908 . 
     Communications unit  910 , in these illustrative examples, provides for communications with other data processing systems or devices. In these illustrative examples, communications unit  910  is a network interface card. 
     Input/output unit  912  allows for input and output of data with other devices that may be connected to data processing system  900 . For example, input/output unit  912  may provide a connection for user input through a keyboard, a mouse, and/or some other suitable input device. Further, input/output unit  912  may send output to a printer. Display  914  provides a mechanism to display information to a user. 
     Instructions for the operating system, applications, and/or programs may be located in storage devices  916 , which are in communication with processor unit  904  through communications framework  902 . The processes of the different embodiments may be performed by processor unit  904  using computer-implemented instructions, which may be located in a memory, such as memory  906 . 
     These instructions are referred to as program code, computer usable program code, or computer readable program code that may be read and executed by a processor in processor unit  904 . The program code in the different embodiments may be embodied on different physical or computer readable storage media, such as memory  906  or persistent storage  908 . 
     Program code  918  is located in a functional form on computer readable media  920  that is selectively removable and may be loaded onto or transferred to data processing system  900  for execution by processor unit  904 . Program code  918  and computer readable media  920  form computer program product  922  in these illustrative examples. In one example, computer readable media  920  may be computer readable storage media  924  or computer readable signal media  926 . 
     In these illustrative examples, computer readable storage media  924  is a physical or tangible storage device used to store program code  918  rather than a medium that propagates or transmits program code  918 . 
     Alternatively, program code  918  may be transferred to data processing system  900  using computer readable signal media  926 . Computer readable signal media  926  may be, for example, a propagated data signal containing program code  918 . For example, computer readable signal media  926  may be an electromagnetic signal, an optical signal, and/or any other suitable type of signal. These signals may be transmitted over communications links, such as wireless communications links, optical fiber cable, coaxial cable, a wire, and/or any other suitable type of communications link. 
     The different components illustrated for data processing system  900  are not meant to provide architectural limitations to the manner in which different embodiments may be implemented. The different illustrative embodiments may be implemented in a data processing system including components in addition to and/or in place of those illustrated for data processing system  900 . Other components shown in  FIG.  9    can be varied from the illustrative examples shown. The different embodiments may be implemented using any hardware device or system capable of running program code  918 . 
     Although the foregoing concepts have been described in some detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. It should be noted that there are many alternative ways of implementing the processes, systems, and apparatus. Accordingly, the present examples are to be considered as illustrative and not restrictive.