Methods of customizing, manufacturing, and repairing a rotor blade using additive manufacturing processes

In a first aspect, there is a method of making a rotor blade, including designing at least one of an upper skin, a lower skin, a support network, and components therefor; and forming at least one of the upper skin, the lower skin, a support network, and components therefor using an additive manufact...

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Bibliographische Detailangaben
Hauptverfasser:	Chiang, Thomas S, Nissen, Jeffrey, Paulson, Jared M
Format:	Patent
Sprache:	eng
Schlagworte:	ADDITIVE MANUFACTURING TECHNOLOGY ADDITIVE MANUFACTURING, i.e. MANUFACTURING OFTHREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVEAGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING,STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING AEROPLANES AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING AIRCRAFT AVIATION BLASTING CASTING CLADDING OR PLATING BY SOLDERING OR WELDING COMBINED OPERATIONS COSMONAUTICS CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING ORREPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR ENGINE PLANTS IN GENERAL GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLYADAPTED FOR USE IN CONNECTION WITH AIRCRAFT HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFTCOMPONENTS, NOT OTHERWISE PROVIDED FOR HEATING HELICOPTERS INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULARARTICLES LIGHTING MACHINE TOOLS MACHINES OR ENGINES FOR LIQUIDS MACHINES OR ENGINES IN GENERAL MAKING METALLIC POWDER MANUFACTURE OF ARTICLES FROM METALLIC POWDER MECHANICAL ENGINEERING METAL-WORKING NOT OTHERWISE PROVIDED FOR NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAMTURBINES OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR OTHER WORKING OF METAL PERFORMING OPERATIONS POWDER METALLURGY PRODUCING MECHANICAL POWER SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDEDFOR SHAPING OR JOINING OF PLASTICS SOLDERING OR UNSOLDERING STEAM ENGINES TRANSPORTING UNIVERSAL MACHINE TOOLS WEAPONS WELDING WIND MOTORS WIND, SPRING WEIGHT AND MISCELLANEOUS MOTORS WORKING BY LASER BEAM WORKING METALLIC POWDER WORKING OF PLASTICS WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL
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Beschreibung
Zusammenfassung:	In a first aspect, there is a method of making a rotor blade, including designing at least one of an upper skin, a lower skin, a support network, and components therefor; and forming at least one of the upper skin, the lower skin, a support network, and components therefor using an additive manufacturing process. In a second aspect, there is an airfoil member having a root end, a tip end, a leading edge, and a trailing edge, the airfoil member including an upper skin; a lower skin; and a support network having a plurality of interconnected support members in a lattice arrangement and/or a reticulated arrangement, the support network being configured to provide tailored characteristics of the airfoil member. Also provided are methods and systems for repairing an airfoil member.