Direct manufacture of aerospace parts

Abstract

A process of fabricating aerospace parts using selective laser sintering is provided, wherein the process generally comprises the steps of preparing a powder nylon material, loading the powder nylon material into a laser sintering machine, warming up the powder nylon material according to build warm-up parameters, building the part according to build parameters and part parameters, and cooling down the part according to build cool-down parameters. As a result, parts are produced that are directly used in aerospace structures, which meet the stringent performance requirements of aerospace applications, rather than as rapid prototypes as with conventional selective laser sintering processes. Additionally, specific designs for aerospace parts such as ducts, panels, and shrouds are provided that are produced by the selective laser sintering process.

What is claimed is:  
     
         1 . A process of fabricating at least one aerospace part, the process comprising the steps of: 
 (a) preparing a powder nylon material;    (b) loading the powder nylon material into a laser sintering machine;    (c) warming up the powder nylon material according to build warm-up parameters, the build warm-up parameters comprising a stage height, feed distances, heater set points, a minimum layer time, and a part heater inner/outer ratio;    (d) building the part according to build parameters, the build parameters comprising feed distances, heater set points, a minimum layer time, and a heater inner/outer ratio; and    (e) cooling down the part according to build cool-down parameters, the build cool-down parameters comprising a stage height, feed distances, heater set points, a minimum layer time, and a heater inner/outer ratio.    
     
     
         2 . The process according to  claim 1 , wherein the stage height build warm-up parameter is between approximately 0.500 in. and approximately 0.855 in  
     
     
         3 . The process according to  claim 1 , wherein the feed distances build warm-up parameters further comprise a left feed distance and a right feed distance build warm-up parameter.  
     
     
         4 . The process according to  claim 3 , wherein the left feed distance build warm-up parameter is approximately 0.01 in. and the right feed distance build warm-up parameter is approximately 0.01 in.  
     
     
         5 . The process according to  claim 1 , wherein the heater set points build warm-up parameters further comprise a left feed heater set point build warm-up parameter, a part heater set point build warm-up parameter, and a right feed heater set point build warm-up parameter.  
     
     
         6 . The process according to  claim 5 , wherein the left feed heater set point build warm-up parameter is between approximately 100° C. and approximately 140° C., the part heater set point build warm-up parameter is between approximately a T glaze -2° C. and approximately a T glaze -4° C., and the right feed heater set point build warm-up parameter is between approximately 100° C. and approximately 140° C.  
     
     
         7 . The process according to  claim 1 , wherein the minimum layer time build warm-up parameter is approximately 30 seconds.  
     
     
         8 . The process according to  claim 1 , wherein the part heater inner/outer ratio build warm-up parameter is between approximately 0.70 and approximately 1.0.  
     
     
         9 . The process according to  claim 1 , wherein the feed distances build parameters further comprise a left feed distance build parameter and a right feed distance build parameter.  
     
     
         10 . The process according to  claim 9 , wherein the left feed distance build parameter is approximately 0.01 in. and the right feed distance build parameter is approximately 0.01 in.  
     
     
         11 . The process according to  claim 1 , wherein the heater set points build parameters further comprise a left feed heater set point build parameter, a part heater set point build parameter, and a right feed heater set point build parameter.  
     
     
         12 . The process according to  claim 11 , wherein the left feed heater set point build parameter is between approximately 100° C. and approximately 140° C., the part heater set point build parameter is between approximately a T glaze -2° C. and approximately a T glaze -6° C., and the right feed heater set point build parameter is between approximately 100° C. and approximately 140° C.  
     
     
         13 . The process according to  claim 1 , wherein the minimum layer time build parameter is between approximately 20 seconds and approximately 30 seconds.  
     
     
         14 . The process according to  claim 1 , wherein the heater inner/outer ratio build parameter is between approximately 0.70 and approximately 1.0.  
     
     
         15 . The process according to  claim 1 , wherein the stage height build cool-down parameter is between approximately 0.015 in. and approximately 0.200 in.  
     
     
         16 . The process according to  claim 1 , wherein the feed distances build cool-down parameters further comprise a left feed distance and a right feed distance build cool-down parameter.  
     
     
         17 . The process according to  claim 16 , wherein the left feed distance build cool-down parameter is approximately 0.01 in. and the right feed distance build cool-down parameter is approximately 0.01 in.  
     
     
         18 . The process according to  claim 1 , wherein the heater set points build cool-down parameters further comprise a left feed heater set point build cool-down parameter, a part heater set point build cool-down parameter, and a right feed heater set point build cool-down parameter.  
     
     
         19 . The process according to  claim 18 , wherein the left feed heater set point build cool-down parameter is between approximately 100° C. and approximately 140° C., the part heater set point build cool-down parameter is between approximately a T glaze -6° C. and approximately a T glaze -45° C., and the right feed heater set point build cool-down parameter is between approximately 100° C. and approximately 140° C.  
     
     
         20 . The process according to  claim 1 , wherein the minimum layer time build cool-down parameter is approximately 10 seconds.  
     
     
         21 . The process according to  claim 1 , wherein the part heater inner/outer ratio build cool-down parameter is between approximately 0.70 and approximately 1.0.  
     
     
         22 . A process of fabricating at least one aerospace part, the process comprising the steps of: 
 (a) preparing a powder nylon material;    (b) loading the powder nylon material into a laser sintering machine;    (c) warming up the powder nylon material;    (d) building the part according to part parameters, the part parameters comprising a fill beam X offset, a fill beam Y offset, a fill laser power, and a sorted fill maximum jump; and    (e) cooling down the part.    
     
     
         23 . The process according to  claim 22 , wherein the fill beam X offset is between approximately −0.005 and approximately −0.01, the fill beam Y offset is between approximately −0.005 and approximately −0.01, the fill laser power is between approximately 15 and approximately 20 watts, and the sorted fill maximum jump is between approximately 0.25 and approximately 0.5.  
     
     
         24 . A process of fabricating at least one aerospace part, the process comprising the steps of: 
 (a) preparing a powder nylon material;    (b) loading the powder nylon material into a laser sintering machine;    (c) warming up the powder nylon material according to build warm-up parameters, the build warm-up parameters comprising a stage height, feed distances, heater set points, a minimum layer time, and a part heater inner/outer ratio;    (d) building the part according to build parameters and part parameters, the build parameters comprising feed distances, heater set points, a minimum layer time, and a heater inner/outer ratio, and the part parameters comprising a fill beam X offset, a fill beam Y offset, a fill laser power, and a sorted fill maximum jump; and    (e) cooling down the part according to build cool-down parameters, the build cool-down parameters comprising a stage height, feed distances, heater set points, a minimum layer time, and a heater inner/outer ratio.    
     
     
         25 . The process according to  claim 24 , wherein the stage height build warm-up parameter is between approximately 0.500 in. and approximately 0.855 in  
     
     
         26 . The process according to  claim 24 , wherein the feed distances build warm-up parameters further comprise a left feed distance and a right feed distance build warm-up parameter.  
     
     
         27 . The process according to  claim 26 , wherein the left feed distance build warm-up parameter is approximately 0.01 in. and the right feed distance build warm-up parameter is approximately 0.01 in.  
     
     
         28 . The process according to  claim 24 , wherein the heater set points build warm-up parameters further comprise a left feed heater set point build warm-up parameter, a part heater set point build warm-up parameter, and a right feed heater set point build warm-up parameter.  
     
     
         29 . The process according to  claim 28 , wherein the left feed heater set point build warm-up parameter is between approximately 100° C. and approximately 140° C., the part heater set point build warm-up parameter is between approximately a T glaze -2° C. and approximately a T glaze -4° C., and the right feed heater set point build warm-up parameter is between approximately 100° C. and approximately 140° C.  
     
     
         30 . The process according to  claim 24 , wherein the minimum layer time build warm-up parameter is between approximately 20 seconds and approximately 30 seconds.  
     
     
         31 . The process according to  claim 24 , wherein the part heater inner/outer ratio build warm-up parameter is between approximately 0.70 and approximately 1.0.  
     
     
         32 . The process according to  claim 24 , wherein the feed distances build parameters further comprise a left feed distance build parameter and a right feed distance build parameter.  
     
     
         33 . The process according to  claim 32 , wherein the left feed distance build parameter is approximately 0.01 in. and the right feed distance build parameter is approximately 0.01 in.  
     
     
         34 . The process according to  claim 24 , wherein the heater set points build parameters further comprise a left feed heater set point build parameter, a part heater set point build parameter, and a right feed heater set point build parameter.  
     
     
         35 . The process according to  claim 34 , wherein the left feed heater set point build parameter is between approximately 100° C. and approximately 140° C., the part heater set point build parameter is between approximately a T glaze -2° C. and approximately a T glaze -6° C., and the right feed heater set point build parameter is between approximately 100° C. and approximately 140° C.  
     
     
         36 . The process according to  claim 24 , wherein the minimum layer time build parameter is between approximately 20 seconds and approximately 30 seconds.  
     
     
         37 . The process according to  claim 24 , wherein the heater inner/outer ratio build parameter is between approximately 0.70 and approximately 1.0.  
     
     
         38 . The process according to  claim 24 , wherein the stage height build cool-down parameter is between approximately 0.015 in. and approximately 0.200 in.  
     
     
         39 . The process according to  claim 24 , wherein the feed distances build cool-down parameters further comprise a left feed distance and a right feed distance build cool-down parameter.  
     
     
         40 . The process according to  claim 39 , wherein the left feed distance build cool-down parameter is approximately 0.01 in. and the right feed distance build cool-down parameter is approximately 0.01 in.  
     
     
         41 . The process according to  claim 24 , wherein the heater set points build cool-down parameters further comprise a left feed heater set point build cool-down parameter, a part heater set point build cool-down parameter, and a right feed heater set point build cool-down parameter.  
     
     
         42 . The process according to  claim 41 , wherein the left feed heater set point build cool-down parameter is between approximately 100° C. and approximately 140° C., the part heater set point build cool-down parameter is between approximately a T glaze -6° C. and approximately a T glaze -45° C., and the right feed heater set point build cool-down parameter is between approximately 100° C. and approximately 140° C.  
     
     
         43 . The process according to  claim 24 , wherein the minimum layer time build cool-down parameter is approximately 10 seconds.  
     
     
         44 . The process according to  claim 24 , wherein the part heater inner/outer ratio build cool-down parameter is between approximately 0.70 and approximately 1.0.  
     
     
         45 . The process according to  claim 24 , wherein the fill beam X offset is between approximately −0.005 and approximately −0.01, the fill beam Y offset is between approximately −0.005 and approximately −0.01, the fill laser power is between approximately 15 watts and approximately 20 watts, and the sorted fill maximum jump is between approximately 0.25 and approximately 0.5.  
     
     
         46 . A process of fabricating at least one aerospace part, the process comprising the steps of: 
 (a) preparing a powder nylon material;    (b) loading the powder nylon material into a laser sintering machine;    (c) warming up the powder nylon material according to build warm-up parameters, the build warm-up parameters comprising a stage height between approximately 0.500 and approximately 0.855 in., a left feed distance of approximately 0.01 in., a right feed distance of approximately 0.01 in., a left feed heater set point between approximately 100° C. and approximately 140° C., a part heater set point between approximately T glaze -6° C. and approximately T glaze -45° C., a right feed heater set point between approximately 100° C. and approximately 140° C., a minimum layer time of approximately 30 seconds, and a part heater inner/outer ratio between approximately 0.70 and approximately 1.0;    (d) building the part according to build parameters and part parameters, the build parameters comprising a left feed distance of approximately 0.01 in., a right feed distance of approximately 0.01 in., a left feed heater set point between approximately 100° C. and approximately 140° C., a part heater set point between approximately T glaze -2° C. and approximately T glaze -6° C., a right feed heater set point between approximately 100° C. and approximately 140° C., a minimum layer time between approximately 20 seconds and approximately 30 seconds, and a heater inner/outer ratio between approximately 0.70 and approximately 1.0, and the part parameters comprising a fill beam X offset between approximately −0.005 in. and approximately −0.01 in., a fill beam Y offset between approximately −0.005 in. and approximately −0.01 in., a fill laser power between approximately 15 watts and approximately 20 watts, and a sorted fill maximum jump between approximately 0.25 and approximately 0.5; and    (e) cooling down the part according to build cool-down parameters, the build cool-down parameters comprising a stage height between approximately 0.015 in. and 0.200 in., a left feed distance build cool-down parameter of approximately 0.01 in., a right feed distance build cool-down parameter of approximately 0.01 in., a left feed heater set point build cool-down parameter between approximately 100° C. and approximately 140° C., a part heater set point build cool-down parameter between approximately a T glaze -6° C. and approximately T glaze -45° C., a right feed heater set point build cool-down parameter between approximately 100° C. and approximately 140° C., a minimum layer time build cool-down parameter of approximately 10 seconds, and a part heater inner/outer ratio build cool-down parameter between approximately 0.70 and approximately 1.0.    
     
     
         47 . An aerospace part formed by a process of: 
 (a) preparing a powder nylon material;    (b) loading the powder nylon material into a laser sintering machine;    (c) warming up the powder nylon material according to build warm-up parameters;    (d) building the part according to build parameters and part parameters; and    (e) cooling down the part according to build cool-down parameters.    
     
     
         48 . The aerospace part according to  claim 47 , wherein the aerospace part comprises an electrical shroud.  
     
     
         49 . The aerospace part according to  claim 47 , wherein the aerospace part comprises a power distribution panel.  
     
     
         50 . The aerospace part according to  claim 47 , wherein the aerospace part comprises a duct.  
     
     
         51 . The aerospace part according to  claim 47 , wherein the aerospace part comprises a fitting.  
     
     
         52 . The aerospace part according to  claim 47 , wherein the aerospace part comprises a closure.  
     
     
         53 . The aerospace part according to  claim 47 , wherein the aerospace part comprises a conduit.  
     
     
         54 . An aerospace part formed by a process of: 
 (a) preparing a powder material;    (b) loading the powder material into a laser sintering machine;    (c) warming up the powder material according to build warm-up parameters;    (d) building the part according to build parameters and part parameters; and    (e) cooling down the part according to build cool-down parameters.    
     
     
         55 . An aerospace duct formed by a process of: 
 (a) preparing a powder material;    (b) loading the powder material into a laser sintering machine;    (c) warming up the powder material according to build warm-up parameters;    (d) building the part according to build parameters and part parameters; and    (e) cooling down the part according to build cool-down parameters.    
     
     
         56 . The aerospace duct according to  claim 55 , wherein the duct comprises at least one internal stiffener.  
     
     
         57 . The aerospace duct according to  claim 55 , wherein the duct comprises at least one mounting pad.