Flexible metallic couplings for drive shafts

A flexible coupling comprising:

• a first flange of a first shaft;
• a second flange of a second shaft, wherein the first flange and the second flange are cylindrical and wherein in a relaxed state the first flange and the second flange are aligned along a longitudinal axis;
• a plurality of first coupling members extending from the first flange, wherein each first coupling member includes:
• a first driving beam extending from the first flange;
• and
• a second driving beam extending from the first flange and meeting the first driving beam at a first node to form a topologically triangular truss;
• and
• a plurality of second coupling members extending from the second flange, wherein each second coupling member includes:
• a first driven beam extending from the second flange;
• and
• a second driven beam extending from the second flange and meeting the first driven beam at a second node to form a topologically triangular truss;
• wherein the first node of each of the first coupling members is connected to the second node of a respective one of the second coupling members;
• and
• wherein each of the first driving beams and second driving beams of the plurality of first coupling members connects to the first flange through a respective branching base, and wherein each of the first driven beams and second driven beams of the plurality of second coupling members connects to the second flange through a respective branching base.

A method of additively manufacturing a flexible coupling, the method comprising:

• forming a first flange of a first shaft starting from a build plate and proceeding in a layer-by-layer additive process in a build direction away from the build plate along the longitudinal axis;
• after forming the first flange, forming a plurality of first coupling members starting from the first flange and proceeding in a layer-by-layer additive process in the build direction, wherein each first coupling member includes a first driving beam extending from the first flange and a second driving beam extending from the first flange and meeting the first driving beam at a first node to form a topologically triangular truss;
• after forming the plurality of first coupling members, forming a plurality of second coupling members, starting from the first nodes and proceeding in a layer-by-layer process in the build direction;
• and
• after forming the plurality of second coupling members, forming a second flange beginning from the second coupling members and proceeding in a layer-by-layer process in the build direction;
• wherein the first node of each of the first coupling members is connected to the second node of a respective one of the second coupling members and wherein each second coupling member includes a first driven beam extending from the second flange and a second driven beam extending from the second flange and meeting the first driven beam at a second node to form a topologically triangular truss.