Method and system for manufacturing an aerostructure

Abstract

An additive manufacturing machine (AMM) operates within a designated work cell. One or more pre-fabricated primary substructure pieces, produced by a first manufacturing process (which can be additive and/or subtractive), are transferred into the designated AMM work cell. The primary substructure pieces are aligned (optionally using alignment structures like rods or tubes which may be temporary aids or permanent stiffeners) and secured within the work cell, typically to a build surface. The alignment structure(s) may also serve as stiffening structure(s). The AMM subsequently deposits additive material onto the aligned primary substructure, using a second, potentially distinct, additive manufacturing process (for example AFP applying one or more tows of pre-impregnated fiber material, such as carbon fiber-reinforced polymer (CFRP). This deposition integrates the primary substructure pieces, permanent stiffening structure(s), and/or builds additional features. During deposition, process parameters such as a heat source (commonly a laser or an infrared (IR) laser), and a compaction member (like a roller) are used to apply energy and pressure to both the newly applied additive material and/or the existing substrate, facilitating adhesion or welding between the materials and ensuring consolidation. Upon completion of the AMM process, the permanent previously separate primary substructure pieces(s), any permanent alignment/stiffening structure(s), and the applied additive material are unified into a single consolidated part.

Dependencies are inferred from the claim text.