Granted Patent B1

US 12,330,214 · App. 16/788,260 · Granted Jun 17, 2025

Inventors: Matthew Perry (Federal Way, WA); Lloyd J. Droppers (Renton, WA); Wade Stahl (Kent, WA)

Assignee: Blue Origin Manufacturing, LLC

B22F10/20B22F3/11B23K26/064B23K26/34B22F10/10B22F2202/11B33Y10/00B33Y80/00

Abstract

Claims (11)

1. A method of manufacturing a porous medium, the method comprising:

selectively heating a first layer of additive material to form an array of first weld beads having a first center, wherein the first weld beads are spaced apart from one another;

selectively heating a second layer of the additive material directly adjacent to the first layer of additive material to form an array of second weld beads having a second center, wherein the second center is laterally offset from the first center, wherein the second weld beads are rotationally offset from the first weld beads by an angle that is not a factor of 360, and wherein the second weld beads are spaced apart from one another; and

selectively heating a third layer of the additive material directly adjacent to the second layer of additive material to form an array of third weld beads having a third center, wherein the second center is laterally offset from the third center, wherein the third weld beads are spaced apart from one another, wherein the first weld beads, the second weld beads, and the third weld beads together form a monolithic structure, and wherein selectively heating the first layer, the second layer, and the third layer includes selectively heating at least one of the first layer, the second layer, and the third layer to attach to a solid portion of a rocket fuel injector so as to directly form the monolithic structure on the solid portion of the rocket fuel injector.

2. The method of claim 1 , wherein the angle is 67°.

3. The method of claim 1 , wherein individual ones of the first and second weld beads are linear, wherein the first weld beads are arranged parallel to one another, and wherein the second weld beads are arranged parallel to one another.

4. The method of claim 1 , wherein the first weld beads are equally spaced apart from one another by a distance, and wherein the second weld beads are also equally spaced apart from one another by the distance.

5. The method of claim 4 , wherein the distance is between 0.1-2.0 millimeter (mm).

6. The method of claim 1 , wherein the first weld beads are non-equally spaced apart, and wherein the second weld beads are non-equally spaced apart.

7. The method of claim 1 , wherein the first weld beads and the second weld beads each have a thickness of 45 micrometer (μm).

8. The method of claim 1 , further comprising depositing the second layer of the additive material over the first layer of the additive material after selectively heating the first layer of the additive material.

Assignments (2)

Continuity (1)

References Cited (173)