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US 10,022,912 B2Granted
Additive manufacturing of a unibody vehicle
AssigneeGM Global Technology Operations LLC
InventorsHamid G. Kia, Ningjian Huang, John P. Spicer, Jorge F. Arinez
Life of this patent
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Abstract
Methods for manufacturing structures are provided. The methods include manufacturing a shell structure by additive manufacturing methods and sectioning panels with predetermined shapes from the shell structure. The panels are subsequently coupled to shell structure. Devices for performing various steps of the methods are also provided.
Claims20
A method for manufacturing a unitary structure, the method comprising:
- additive manufacturing a shell template of the unitary structure in a layer-by-layer printing process, wherein the shell template comprises an interior surface and an exterior surface;
- applying a reinforcing material to the exterior surface of the shell template;
- treating the reinforcing material to generate a reinforced shell comprising a reinforcing composite;
- sectioning at least one panel with a predetermined shape out of the reinforced shell at a predetermined location;
- removing the panel from the reinforced shell;
- and
- coupling the panel to the reinforced shell such that the panel is operable to open and close at the predetermined location from where the panel was removed from the reinforced shell.
4 more elements
A method for manufacturing a unitary structure, the method comprising:
- additive manufacturing a shell template of the unitary structure in a layer-by-layer printing process, wherein the shell template comprises an interior surface and an exterior surface;
- sectioning at least one panel with a predetermined shape out of the shell template at a predetermined location;
- removing the at least one panel from the shell template;
- modifying the at least one panel or the shell template by creating at least one layer of material on an edge of the shell template or panel that is exposed when the panel is removed via additive manufacturing;
- and
- coupling the at least one panel to the shell template at the predetermined location.
3 more elements
A method for manufacturing a unibody of a vehicle;
- the method comprising:
- generating a shell template via a layer-by-layer additive manufacturing process, wherein the shell template comprises an interior surface and an exterior surface;
- applying a reinforcing composite material precursor to the exterior surface of the shell template comprising a resin and a plurality of fibers;
- treating the reinforcing composite material precursor to generate a reinforced shell;
- sectioning one or more panels with predetermined shapes out of the reinforced shell at one or more predetermined locations;
- removing the one or more panels from the reinforced shell;
- generating a frame structure about the interior surface of the reinforced shell via a layer-by-layer additive manufacturing process;
- and
- coupling the one or more panels to the reinforced shell at the corresponding one or more predetermined locations, wherein the one or more panels correspond to a vehicle component selected from the group consisting of doors, trunk lids, hoods, hatchbacks, fuel door covers, electrical outlet doors, scoops, and combinations thereof.
6 more elements
Dependencies are inferred from the claim text.