Methods and apparatus for manufacturing optimized panels and other composite structures

Abstract

The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component.

1 . A panel for use in a transport structure, comprising;
 at least one face sheet; and   an additively manufactured (AM) core affixed to the at least one face sheet and configured to provide a varying strength across at least a portion of the AM core for supporting expected load conditions determined across all three coordinate axes (x,y,z).   
     
     
         2 . The panel of  claim 1 , wherein the at least one face sheet comprises a non-planar contour. 
     
     
         3 . The panel of  claim 1 , wherein the at least one face sheet comprises a variable thickness. 
     
     
         4 . The panel of  claim 1 , wherein the AM core comprises a homogenous material. 
     
     
         5 . The panel of  claim 1 , wherein the AM core is configured to provide a varying strength along a plurality of directions. 
     
     
         6 . The panel of  claim 1 , wherein the expected load conditions comprise forces asserted in three dimensions. 
     
     
         7 . The panel of  claim 1 , wherein the expected load conditions comprise forces asserted from a plurality of directions. 
     
     
         8 . The panel of  claim 1 , wherein the expected load conditions comprise forces asserted on either or both of the panel or the AM core. 
     
     
         9 . The panel of  claim 1 , wherein the expected load conditions comprise forces asserted on a plurality of locations of the panel or the AM core. 
     
     
         10 . The panel of  claim 1 , wherein the AM core is further configured to provide values for one or more of a varying stiffness, rigidity, flexibility, ductility, density, energy absorption, and crush across one or more portions of the AM core for supporting the expected load conditions. 
     
     
         11 . The panel of  claim 10 , wherein the one or more of a varying stiffness, rigidity, flexibility and density vary in a plurality of directions in the AM core. 
     
     
         12 . The panel of  claim 1 , wherein the expected load conditions are derived from an intended application of the panel. 
     
     
         13 . The panel of  claim 1 , wherein the AM core comprises a modified honeycomb structure. 
     
     
         14 . The panel of  claim 1 , wherein the at least one face sheet is 3-D printed and has a contoured shape to form a non-flat panel when joined with the AM core. 
     
     
         15 . The panel of  claim 1 , wherein the at least one face sheet is formed and has a contoured shape to form a non-flat panel when joined with the AM core. 
     
     
         16 . The panel of  claim 1 , wherein
 the at least one face sheet comprises first and second face sheets,   the AM core is affixed between the first and second face sheets, and   the first and second face sheets are one of 3-D printed or formed and have contoured shapes to form a non-flat panel when joined with the AM core.   
     
     
         17 . The panel of  claim 16 , further comprising:
 a first adhesive layer configured to adhere the first face sheet to a first side of the AM core; and   a second adhesive layer configured to adhere the second face sheet to a second side of the AM core.   
     
     
         18 . The panel of  claim 1 , wherein the AM core is quasi-isotropic. 
     
     
         19 . The panel of  claim 1 , wherein the AM core one of anisotropic or orthotropic based on an intended panel application. 
     
     
         20 . The panel of  claim 1 , wherein the first and second face sheets comprise a carbon fiber reinforced composite material. 
     
     
         21 - 65 . (canceled)