Monolithic and integrally formed hinge structure for an aircraft
In accordance with one embodiment of the present disclosure, an aircraft assembly is described. The aircraft assembly can include an airfoil structure, which can extend in a chordwise direction from a leading edge to a trailing edge and can include a first component having one or more hinge loops. The first component can have one or more hinge loops that include a first monolithic, integrally formed structure. The airfoil structure can also include a rear component positioned behind the first component in the chordwise direction. The rear component can have an interface member extending within the one or more hinge loops. The rear component, including the interface member, can include a second monolithic, integrally formed structure.
1 . A method of manufacturing an airfoil structure of an aircraft assembly, the airfoil structure extending in a chordwise direction from a leading edge to a trailing edge, the method comprising:
printing, on a 3D printer platform using an additive manufacturing process, a first component of the airfoil structure as a first monolithic, integrally formed structure, wherein the first component includes one or more hinge loops; and
during printing of the first component, printing, on the 3D printer platform using the additive manufacturing process, a rear component of the airfoil structure as a second monolithic, integrally formed structure, wherein the rear component includes an interface member extending within the one or more hinge loops.
2 . The method of claim 1 , wherein:
the additive manufacturing process includes depositing a plurality of layers on the 3D printer platform;
the first component includes a plurality of first-component layers;
the rear component includes a plurality of rear-component layers; and
the method further comprises depositing, in a first sequence of co-component layers of the plurality of layers, a first sequence of the plurality of rear-component layers and a first sequence of the plurality of first-component layers.
3 . The method of claim 2 , further comprising maintaining, throughout the printing of the first component and the printing of the rear component, a clearance gap between the plurality of rear-component layers and the plurality of first-component layers, the clearance gap sufficient to prevent fusion between the plurality of rear-component layers and the plurality of first-component layers.
4 . The method of claim 2 , wherein the first sequence of rear-component layers includes a portion of the interface member and the first sequence of first-component layers includes a portion of the one or more hinge loops, and wherein the portion of the one or more hinge loops circumscribes the portion of the interface member.
5 . The method of claim 4 , wherein the portion of the one or more hinge loops is circumferentially closed within the first sequence of co-component layers.
6 . The method of claim 4 , wherein printing the rear component includes printing a body portion positioned behind the interface member in the chordwise direction and printing one or more attachment portions affixing the interface member to the body portion.
7 . The method of claim 6 , further comprising depositing, in a second sequence of co-component layers of the plurality of layers, a second sequence of the plurality of rear-component layers and a second sequence of the plurality of first-component layers, wherein the second sequence of rear-component layers includes a portion of the body portion and a portion of the one or more attachment portions, and the second sequence of first-component layers is offset, in a stacking direction of the plurality of layers, from each of the one or more hinge loops.
8 . The method of claim 6 , wherein printing the rear component comprises printing a free edge of at least one of the one or more attachment portions, the free edge tapering outward at an acute angle relative to a stacking direction of the plurality of layers.
9 . The method of claim 2 , wherein printing the first component comprises printing a free edge of at least one of the one or more hinge loops, the free edge tapering outward at an acute angle relative to a stacking direction of the plurality of layers.
10 . The method of claim 2 , wherein printing the rear component comprises printing an inner surface of the interface member, the inner surface defining a passage configured to receive a steering member therein, wherein the inner surface is configured to engage a keyed outer surface of the steering member to pivot the rear component relative to the first component in response to rotational motion of the steering member.
11 . The method of claim 10 , wherein the inner surface of the interface member has a second hexagonal shape configured to be complementary to a first hexagonal shape of an outer surface of the steering member.
12 . The method of claim 1 , wherein printing the rear component comprises printing at least one feature extending outward from the interface member, the at least one feature configured to be driven by a motor to pivot the rear component relative to the first component.
13 . The method of claim 12 , wherein printing the at least one feature comprises printing a first gear member configured for geared cooperation with a second gear member driven by a motor.
14 . The method of claim 1 , wherein the interface member of the rear component has an outer surface that has a cylindrical shape, wherein the interface member extends within the one or more hinge loops of the first component such that the outer surface of the interface member is concentric with the one or more hinge loops.
15 . The method of claim 1 , wherein the one or more hinge loops comprises a plurality of hinge loops, and the interface member extends within each of the plurality of hinge loops.