Hybrid composite structures with integrated 3-D printed elements

1. An additively manufactured (AM) hybrid composite structure comprising:

a first portion comprising a first material; and

a second portion comprising a second material, the second portion being configured to integrate with the first portion, the second portion further comprising one or more AM elements configured to enable integration of the second portion with the first portion to form an integrated component including both the second portion and the first portion.

2. The AM hybrid composite structure of claim 1 , wherein the first portion comprises a composite layup.

3. The AM hybrid composite structure of claim 1 , wherein the second portion comprises an additively manufactured (AM) tool.

4. The AM hybrid composite structure of claim 3 , wherein the AM tool comprises a tooling shell and an AM internal core.

5. The AM hybrid composite structure of claim 4 , wherein the one or more AM elements are co-printed with the AM internal core.

6. The AM hybrid composite structure of claim 1 , wherein the integrated component is further configured for assembly into a transport structure.

7. The AM hybrid composite structure of claim 1 , wherein the one or more AM elements are further configured to eliminate an external tool to integrate the second portion with the first portion.

8. The AM hybrid composite structure of claim 1 , wherein the one or more AM elements comprise one or more guidelines.

9. The AM hybrid composite structure of claim 8 , wherein the first portion comprises one or more composite plies.

10. The AM hybrid composite structure of claim 9 , wherein the one or more composite plies are pre-stacked.

11. The AM hybrid composite structure of claim 9 , wherein the one or more guidelines are configured to assist placement of the one or more composite plies.

12. The AM hybrid composite structure of claim 9 , wherein the second portion comprises an additively manufactured (AM) tool, wherein the one or more guidelines are co-printed with the AM tool.

13. The AM hybrid composite structure of claim 9 , wherein the one or more guidelines comprises one or more sets of guidelines configured to provide instructions and boundaries for trimming operation of the one or more composite plies.

14. The AM hybrid composite structure of claim 9 , wherein the one or more guidelines comprises one or more text or numerical instructions.

15. The AM hybrid composite structure of claim 9 , wherein the one or more guidelines comprises one or more edge markings.

16. The AM hybrid composite structure of claim 8 , wherein the one or more AM elements are configured to be a part of a placement tool.

17. The AM hybrid composite structure of claim 1 , wherein the one or more AM elements comprise one or more ports and one or more channels.

18. The AM hybrid composite structure of claim 17 , wherein the one or more AM elements comprise a part of a vacuum tool.

19. The AM hybrid composite structure of claim 17 , wherein the one or more AM elements comprise a part of a resin infusion tool.

20. The AM hybrid composite structure of claim 17 , wherein the first portion comprises a composite ply, wherein the second portion comprises an AM tool, and wherein the one or more ports are disposed on an exterior surface of the AM tool.

21. The AM hybrid composite structure of claim 20 , wherein the one or more channels extend inward from a respective one or more ports on the exterior surface of the AM tool.

22. The AM hybrid composite structure of claim 17 , wherein the one or more ports are configured to enable a negative pressure to be applied via an associated one or more channels to the first portion.

23. The AM hybrid composite structure of claim 17 , wherein the one or more ports are configured to enable resin to be infused via an associated one or more channels into the first portion.

24. The AM hybrid composite structure of claim 17 , wherein a first set of the one or more ports, via an associated one or more channels, is configured to enable a negative pressure to be applied to the first portion, and a second set of the one or more ports, via an associated one or more channels, is configured to enable resin to be infused into the first portion.

25. A method of manufacturing a hybrid composite structure, comprising:

manufacturing a first portion;

additively manufacturing a second portion, comprising co-printing one or more additively manufactured (AM) elements;

using the one or more AM elements as a part of a tool to integrate the first portion with the second portion; and

forming an integrated component including both the first portion and the second portion.

26. The method of claim 25 , wherein the one or more AM elements comprise one or more guidelines, and wherein the first portion comprises one or more composite plies.

27. The method of claim 26 , wherein using the one or more AM elements as a part of the tool comprises using the one or more guidelines to assist placing the one or more composite plies.

28. The method of claim 26 , further comprising pre-stacking the one or more composite plies.

29. The method of claim 26 , wherein using the one or more AM elements as a part of the tool comprises using the one or more guidelines to assist orientation of the one or more composite plies.

30. The method of claim 25 , wherein the one or more AM elements comprise one or more ports and one or more channels.

31. The method of claim 30 , wherein using the one or more AM elements as a part of the tool comprises using the one or more AM elements to enable negative pressure to be applied to the first portion.

32. The method of claim 30 , wherein using the one or more AM elements as a part of the tool comprises using the one or more AM elements to enable resin to be infused into the first portion.

33. The method of claim 30 , wherein the second portion comprises a tooling shell and an AM internal core, wherein co-printing one or more AM elements comprises co-printing one or more AM ports with the tooling shell.

34. The method of claim 30 , wherein the second portion comprises a tooling shell and an AM internal core, wherein co-printing one or more AM elements comprises co-printing one or more AM channels with the AM internal core.

35. The method of claim 30 , wherein co-printing one or more AM elements comprises co-printing one or more AM ports, a first portion of the one or more ports being configured to enable a negative pressure to be applied to the first portion, a second portion of the one or more ports being configured to enable resin to be infused into the first portion.

36. The method of claim 30 , wherein co-printing one or more AM elements comprises co-printing one or more AM channels, a first set of the one or more channels being configured to enable negative pressure to be applied to the first portion, a second set of the one or more channels being configured to enable resin to be infused into the first portion.