# US 11,440,245 B2 · Additive manufacturing method for a turbofan engine oil tank > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,440,245 B2 - Document ID: US11440245B2 - Status: Granted - Kind: B2 - Application number: 15/727,708 - Filed: 2017-10-09 - Published: 2018-04-19 - Granted: 2022-09-13 - Earliest claimed: 2017-10-09 - Assignees: Safran Aero Boosters SA - Applicants: Safran Aero Boosters SA - Inventors: Stephane Bougelet; Florian Cleyet; Tom Henkes; Bruno Servais - Web page: https://patentgrep.com/patent/US11440245B2 ## CPC - B22F 5/10: of articles with cavities or holes, not otherwise provided for in the preceding subgroups - B22F 7/04: with one or more layers not made from powder, e.g. made from solid metal - B22F 7/06: of composite workpieces or articles from parts, e.g. to form tipped tools {(B22F7/002 takes precedence)} - B22F 7/062: {involving the connection or repairing of preformed parts} - B22F 10/25: Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] - B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] - B29C 64/147: using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object - B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting - B33Y 10/00: Processes of additive manufacturing - B33Y 80/00: Products made by additive manufacturing - F16N 19/00: Lubricant containers for use in lubricators or lubrication systems - B22F 5/009: {of turbine components other than turbine blades (of turbine blades B22F5/04)} - B22F 10/66: by mechanical means - B22F 2007/042: {characterised by the layer forming method} - B29L 2031/7172: {Fuel tanks, jerry cans} - Y02P 10/25: Process efficiency - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - F16N: LUBRICATING - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract The invention relates to a method of manufacturing at least one tank with a shell, in particular a turbojet engine oil tank. The method comprises the following stages: (a) definition of different shell sections (58) for each tank, whereof a first shell section (58) has a recess (60) and a second shell section (58) a boss (62); (b) production of the shell sections (58) by additive manufacturing in which the boss (62) on the second shell section is produced in the recess (60) in the first shell section; then (c) welding of the sections (60) one to the other. ## Claims ### Claim 1 A manufacturing method of at least one turbojet engine tank with a shell, said method comprising the following stages: definition of different shell sections for each tank, whereof a first shell section includes a recess, a second shell section includes a boss and a third shell section comprises a recess and a boss, wherein the recess of the first shell section is of a shape matching the shape of the boss of the second shell section; and production of the shell sections by additive manufacturing, wherein the production stage comprises the production by additive manufacturing of the boss of the second shell section within the recess of the first shell section, wherein the first shell section, the second shell section, and the third shell section each comprise a spheroidal portion and a tubular portion, said spheroidal portion defining a respective central spheroidal radial direction and said tubular portion defining a respective central tubular radial direction, said spheroidal portions being embedded one in the other at the end of the production stage, and said tubular portions being embedded one in the other at the end of the production stage, wherein the production stage comprises the production by additive manufacturing of the boss of the second shell section and the boss of the third shell section within the recess of the first shell section; the third shell section being embedded in the recess of the first shell section through the boss of the second shell section, wherein the production stage is such that at the end of the production stage, the first, second and third shell sections are offset with respect to one another in such a way that their respective central spheroidal radial direction coincide and their respective central tubular radial direction coincide. ### Claim 2 (depends on 1) The manufacturing method in accordance with claim 1, wherein at the end of the production stage, the recess of the first shell section surrounds the boss of the second shell section, or at least a portion of the boss of the second shell section. ### Claim 3 (depends on 1) The manufacturing method in accordance with claim 1, wherein the recess of the first shell section forms a cup in which the boss of the second shell section is disposed at the end of the production stage. ### Claim 4 (depends on 1) The manufacturing method in accordance with claim 1, wherein at the end of the production stage, the surface of the boss of the second shell section is within the recess of the first shell section. ### Claim 5 (depends on 1) The manufacturing method in accordance with claim 1, wherein each spheroidal portion forms an eighth of a sphere or a quarter of a sphere or a half-sphere. ### Claim 6 (depends on 1) The manufacturing method in accordance with claim 1, wherein at the end of the production stage, the first shell section comprises a mounting flange and the second shell section comprises a stiffener which projects from its recess. ### Claim 7 (depends on 1) The manufacturing method in accordance with claim 1, wherein from the point of view of the first shell section, at the end of the production stage, the second shell section hides the third shell section. ### Claim 8 (depends on 1) The manufacturing method in accordance with claim 1, wherein additive manufacturing is manufacturing through the addition of layers, in particular additive manufacturing with powder-based layers. ### Claim 9 (depends on 1) The manufacturing method in accordance with claim 1, wherein during the production stage, additive manufacturing is carried out in an additive manufacturing machine in a pocket delimited by fixed lateral walls. ### Claim 10 (depends on 1) The manufacturing method in accordance with claim 1, further comprising a welding stage of the shell sections produced during the production stage. ### Claim 11 (depends on 1) The manufacturing method in accordance with claim 1, wherein at the end of the production stage, the shell sections are shell sections of the same tank or of two different tanks.