Granted Patent B2

US 12,303,994 · App. 18/365,125 · Granted May 20, 2025

Inventors: Michael L. Bailey (Montgomery, TX); Weidong Song (Woodinville, WA)

Assignee: Blue Origin Manufacturing, LLC

B23K20/1215B23K20/1255B23K20/128B23K20/129B33Y10/00B33Y80/00B23K2103/10

Abstract

Claims (34)

1. A method of additive manufacturing a part comprising:

forming a first part and a second part separate from the first part, each part having a near net shape, the first part and the second part formed by moving a friction stir tool configured to deposit a filler material;

machining an inner surface of each part;

joining the first part and the second part to form a structure, the inner surfaces of the first part and the second part configured to define an interior space of the structure;

machining an outer surface of the structure;

machining a plurality of grooves extending into the outer surface of the structure, the plurality of grooves sized to each receive a tube;

placing a tube into each of the plurality of grooves;

depositing a layer of material configured to secure the tubes within the plurality of grooves by moving the friction stir tool across the outer surface of the structure; and

machining the outer surface of the structure to form a predetermined shape.

2. The method of claim 1 , wherein the first part and the second part are hemispheres.

3. The method of claim 1 , wherein the tubes are configured to transport a liquid for heat exchange.

4. The method of claim 1 , wherein the structure has a cylindrical shape.

5. The method of claim 1 , wherein the structure is a tank.

6. The method of claim 1 , wherein joining the first part and the second part comprises at least one of welding, gluing, melting, and fastening the first part and the second part to form the structure.

7. The method of claim 1 , wherein the friction stir tool comprises a spindle having a channel extending along a central axis of the spindle and configured to hold the filler material, and wherein forming a first part and a second part comprises rotating the spindle of the friction stir tool to deposit the filler material held in the channel.

8. A method of additive manufacturing a part comprising:

forming a first part having a near net shape and a second part having a near net shape, by depositing layers of material using a friction stir tool, a new layer added to a surface of a previously deposited layer;

joining the first part and the second part to form a structure, an inner surface of the first part and an inner surface of the second part configured to define an interior space of the structure;

machining a plurality of grooves extending into an outer surface of the structure, the plurality of grooves sized to each receive a wire;

positioning a wire into each of the plurality of grooves;

securing the wires within the plurality of grooves with additional material deposited over the wires; and

machining the outer surface of the structure to form a predetermined shape.

9. The method of claim 8 , further comprising machining the inner surface of the first part and the inner surface of the second part.

10. The method of claim 8 , wherein the first part and the second part are hemispheres.

11. The method of claim 8 , wherein the structure has a cylindrical shape.

12. The method of claim 8 , wherein the structure is a tank and the interior space is configured to hold a gas or a liquid.

13. The method of claim 8 , wherein the wires comprise hollow wires.

14. The method of claim 13 , wherein the hollow wires are configured to transport a gas or a liquid for heat exchange.

15. The method of claim 8 , wherein the wires comprise solid wires.

16. The method of claim 15 , wherein the wires comprise solid aluminum wires.

17. The method of claim 15 , further comprising removing the solid wires from the predetermined shape using a chemical or thermal process.

18. The method of claim 8 , wherein the material is a first material and the wires are formed of a second material different than the first material.

19. The method of claim 8 , wherein the material is a first material and the wires are formed of a second material that is the same as or substantially the same as the first material.

20. The method of claim 8 , wherein joining the first part and the second part comprises at least one of welding, gluing, melting, and fastening the first part and the second part to form the structure.

Assignments (2)

Continuity (1)

References Cited (400)

Cited By (4)

US 12,558,739 US 12,630,313 US 12,643,687 US 12,661,713