Injection molding stitching for structural reinforcement

1 . A computer-implemented method for repairing a structural defect, comprising:

determining a size and position of an internal defect within a structural element;

in accordance with a structural analysis of the internal defect, determining a stitching pattern that counters loss of structural integrity due to the internal defect;

forming a set of through holes and channels within the structural element in accordance with the stitching pattern, wherein at least one of the set of through holes is directly connected to two other of the set of through holes via respective channels; and

filling the set of through holes and channels in the structural element around the internal defect in accordance with the stitching pattern to increase strength around the internal defect.

2 . The method of claim 1 , wherein determining the size and position of the internal defect includes scanning the structural element using a penetrating energy source.

3 . The method of claim 1 , wherein determining the stitching pattern includes determining a number of stitches relative to a position of the internal defect and a diameter of the set of through holes and channels.

4 . The method of claim 1 , wherein forming the set of through holes and channels in the structural element in accordance with the stitching pattern includes employing a robot milling tool.

5 . The method of claim 1 , wherein filling the set of through holes and channels includes injection molding a material in the set of through holes and channels.

6 . The method of claim 1 , wherein filling the set of through holes and channels includes three dimensional printing a material in the set of through holes and channels.

7 . The method of claim 1 , further comprising supporting the structural element during forming of the set of through holes and channels.

8 . The method of claim 1 , further comprising determining whether a repair is feasible.

9 . A system for repairing a structural defect, comprising:

a hardware processor; and

a memory that stores a computer program which, when executed by the hardware processor, causes the hardware processor to:

determine a size and position of an internal defect within a structural element;

in accordance with a structural analysis of the internal defect, determine a stitching pattern that counters loss of structural integrity due to the internal defect;

form, with a computer controlled milling tool, a set of through holes and channels within the structural element in accordance with the stitching pattern, wherein at least one of the set of through holes is directly connected to two other of the set of through holes via respective channels; and

fill, with a computer controlled filling tool, the set of through holes and channels in the structural element around the internal defect in accordance with the stitching pattern to increase strength around the internal defect.

10 . The system of claim 9 , wherein the size and position of the internal defect are determined using a penetrating energy source on the structural element.

11 . The system of claim 9 , wherein the stitching pattern includes a number of stitches relative to a position of the internal defect and a diameter of the set of through holes and channels.

12 . The system of claim 9 , wherein the computer controlled milling tool includes a robot milling tool.

13 . The system of claim 9 , wherein the computer controlled filling tool includes an injection molding device.

14 . The system of claim 9 , wherein the computer controlled filling tool includes a three dimensional printer.