CN117921137A - Arc additive manufacturing method of composite material complex curved surface tool structure - Google Patents
Arc additive manufacturing method of composite material complex curved surface tool structure Download PDFInfo
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- CN117921137A CN117921137A CN202410213035.7A CN202410213035A CN117921137A CN 117921137 A CN117921137 A CN 117921137A CN 202410213035 A CN202410213035 A CN 202410213035A CN 117921137 A CN117921137 A CN 117921137A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 72
- 239000000654 additive Substances 0.000 title claims abstract description 47
- 230000000996 additive effect Effects 0.000 title claims abstract description 47
- 239000002131 composite material Substances 0.000 title claims abstract description 28
- 238000000034 method Methods 0.000 claims abstract description 39
- 238000000465 moulding Methods 0.000 claims abstract description 5
- 239000000758 substrate Substances 0.000 claims description 26
- 238000010438 heat treatment Methods 0.000 claims description 15
- 238000003754 machining Methods 0.000 claims description 10
- 238000001514 detection method Methods 0.000 claims description 9
- 238000005520 cutting process Methods 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 4
- 230000001681 protective effect Effects 0.000 claims description 3
- 239000006104 solid solution Substances 0.000 claims description 3
- 238000002360 preparation method Methods 0.000 claims description 2
- 230000008569 process Effects 0.000 abstract description 17
- 239000000463 material Substances 0.000 abstract description 4
- 239000011229 interlayer Substances 0.000 abstract description 3
- 238000005516 engineering process Methods 0.000 abstract description 2
- 238000005457 optimization Methods 0.000 abstract description 2
- 239000002699 waste material Substances 0.000 abstract description 2
- 239000010410 layer Substances 0.000 description 9
- 238000012545 processing Methods 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- 239000000243 solution Substances 0.000 description 4
- 238000003466 welding Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 238000004088 simulation Methods 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910001374 Invar Inorganic materials 0.000 description 1
- 229910000746 Structural steel Inorganic materials 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 230000007480 spreading Effects 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/04—Welding for other purposes than joining, e.g. built-up welding
- B23K9/044—Built-up welding on three-dimensional surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y50/00—Data acquisition or data processing for additive manufacturing
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Mechanical Engineering (AREA)
- Mounting, Exchange, And Manufacturing Of Dies (AREA)
Abstract
The invention discloses an arc additive manufacturing method of a complex curved surface tooling structure of a composite material, which belongs to the technical field of production and manufacturing, and can realize rapid manufacturing and mass production application of complex curved surface tooling, and the specific scheme is as follows: the method comprises the following steps: layering and slicing the tooling model based on the tooling model; planning a path of the tool molding; the method comprises the steps of filling paths along parallel lines of a short side of a tooling model in a reciprocating manner during path planning; and carrying out tooling forming based on the layering slice information and the path planning information. The invention adopts the arc fuse additive manufacturing technology to directly manufacture the conduit tool structure, has the advantages of no need of a die, direct manufacture of a complex structure, high manufacturing efficiency and the like, and can realize the rapid delivery and use of the tool structure; the invention adopts the process parameter matching, the forming path optimization and the interlayer temperature control, can improve the precision of arc additive manufacturing, reduce material waste and save manufacturing cost.
Description
Technical Field
The invention belongs to the technical field of production and manufacturing, and particularly relates to an arc additive manufacturing method of a complex curved surface tooling structure of a composite material.
Background
With the continuous improvement of the requirements of advanced aircrafts on high-altitude flight, strong maneuverability and the like and the requirements on fuel economy, lightweight high-performance composite materials are widely applied to aircrafts. In the manufacturing process of the composite material, the component and the forming tool are required to be cured and formed together at high temperature in an autoclave, the component of the composite material can generate uncontrollable deformation when the component is restored to the room temperature working condition from the high-temperature forming, and the deformation is required to be controlled by adopting the tool. At present, the deformation of the Invar steel tool is mainly controlled in the manufacturing process of the composite tool. The traditional tool structure is obtained by rolling, casting or assembling and welding, and has the problems of high manufacturing difficulty, long manufacturing period and the like for the tool with complex curved surfaces, so that the manufacturing of aircraft composite parts is severely restricted.
For example, patent CN105013905A proposes a "process method for integrally forming a large curved surface composite material tooling steel plate", which requires about 10mm of machining allowance to be added, and the integral forming processing of the large curved surface composite material tooling steel plate is realized through the steps of bending and preforming a steel plate roller, heat treatment, spreading hot carbon, filling steel balls, vibration, heating and the like. The method has the advantages of complex manufacturing flow and long manufacturing period, and cannot realize the manufacturing of the complex curved surface tool.
Disclosure of Invention
The invention provides an arc additive manufacturing method of a complex curved surface tooling structure of a composite material, which can realize the rapid manufacturing and mass production application of complex curved surface tooling.
The invention is realized by the following technical scheme:
The invention provides an arc additive manufacturing method of a complex curved surface tooling structure of a composite material, which comprises the following steps of: layering and slicing the tooling model based on the tooling model; planning a path of the tool molding; the method comprises the steps of filling paths along parallel lines of a short side of a tooling model in a reciprocating manner during path planning; and carrying out tooling forming based on the layering slice information and the path planning information.
In some of these embodiments, tooling forming based on the hierarchical slice information and the fill path includes: selecting a substrate; injecting protective gas into the tool forming working cavity; setting technological parameters for tooling forming; and (5) performing tooling forming to obtain a tooling blank.
In some of these embodiments, the substrate thickness is selected to be 30-50mm.
In some of these embodiments, the injected shielding gas is a mixture of 85% ar+15% co 2.
In some of these embodiments, the process parameters used for tooling include: layering slice thickness l=2-5 mm, wire feed speed vf=6.5-7.5 m/min, current i=115-135A, voltage u=13-18V, forming speed vw=10-15 mm/s, forming pitch h=1.8-3.0 mm.
In some of these embodiments, the tooling mold layer temperature is 150-200 ℃.
In some embodiments, after the tooling forming, the tooling blank is obtained, the method further comprises the following steps: carrying out heat treatment on the tooling blank with the substrate, and comprising: the solid solution temperature is 1000-1060 ℃, the heat treatment time is 4-6h, and the mixture is cooled to room temperature.
In some embodiments, after the heat treatment of the tooling blank with the substrate, the method further comprises the following steps: and taking out the redundant substrate by adopting linear cutting to obtain a finished product of the tool.
In some embodiments, the wire cutting is adopted to take out the redundant substrate, and after the tooling finished product is obtained, the method further comprises the following steps: detect frock finished product, include: carrying out ultrasonic flaw detection and/or X-ray nondestructive detection on the structure of the finished product of the processed tool; air tightness detection is carried out; and detecting the structural size of the finished product of the tool by adopting three coordinates.
In some of these embodiments, before slicing the model in layers based on the tooling model, the method further comprises the steps of: the method for obtaining the tooling model specifically comprises the following steps: in the preparation process of the tooling model, carrying out integral inverse deformation structure compensation on the area with the deformation of the tooling model being more than 10-15%; and adding 3-6mm of machining allowance compensation to the tool mounting surface and/or the profile matching surface.
Compared with the prior art, the invention has the following advantages:
1. The invention adopts the arc fuse additive manufacturing technology to directly manufacture the conduit tool structure, has the advantages of no need of a die, direct manufacture of a complex structure, high manufacturing efficiency and the like, and can realize the rapid delivery and use of the tool structure;
2. The invention adopts the process parameter matching, the forming path optimization and the interlayer temperature control, so that the precision of arc additive manufacturing can be improved, the material waste can be reduced, and the manufacturing cost can be saved;
3. The invention can be used for the rapid development and mass production stage of complex curved surface tooling of composite materials, and improves the production and manufacturing efficiency of products.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following description will briefly describe the drawings in the embodiments, it being understood that the following drawings only illustrate some embodiments of the present invention and should not be considered as limiting the scope, and that other related drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a process flow diagram of an arc additive manufacturing method of a complex curved tooling structure of a composite material provided by an embodiment of the invention;
FIG. 2 is a process flow diagram of an arc additive manufacturing method for a composite complex curved tooling structure according to further embodiments of the present invention;
fig. 3 is a schematic diagram of a forming path of an arc additive manufacturing method of a complex curved tooling structure of a composite material.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention.
In the description of the present invention, it should be noted that, as the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., are used to indicate orientations or positional relationships based on those shown in the drawings, or those that are conventionally put in use in the product of the present invention, they are merely used to facilitate description of the present invention and simplify description, and do not indicate or imply that the apparatus or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present invention.
Furthermore, the terms "horizontal," "vertical," and the like in the description of the present invention, if any, do not denote absolute levels or overhangs, but rather may be slightly inclined. As "horizontal" merely means that its direction is more horizontal than "vertical", and does not mean that the structure must be perfectly horizontal, but may be slightly inclined.
In the description of the present invention, it should also be noted that, unless explicitly stated and limited otherwise, the terms "disposed," "mounted," "connected," and "connected" should be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
The terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, system, article, or apparatus that comprises a list of steps or modules is not limited to only those steps or modules but may include other steps or modules not expressly listed or inherent to such process, method, article, or apparatus.
The embodiment provides an arc additive manufacturing method of a complex curved surface tooling structure of a composite material, as shown in fig. 1 and 2, comprising the following steps:
S10, acquiring a tool model. In S10, an initial tooling model is prepared according to requirements, then a certain pretreatment is carried out on the initial tooling model, and arc additive manufacturing is carried out by taking the pretreated tooling model as a reference standard, so that batch tooling is obtained.
Wherein S10 has the steps of:
S101, performing inverse deformation structure compensation on the tool model partial region. In S101, after the initial tooling model is prepared, the deformation resistance of different regions is different due to different structures of the tooling model. For the region with weak deformation resistance, in the subsequent arc additive manufacturing process, the generated tooling is influenced by the influence of the working environment, so that the region with weak deformation resistance needs to be subjected to deformation structure compensation in advance. The integral anti-deformation structure compensation is carried out on the area with the deformation of the tooling model being more than 10-15% in an exemplary way. Specifically, deformation simulation analysis is carried out on the tool structure before additive manufacturing to obtain the structural deformation trend of the tool structure, inverse deformation structural design compensation is carried out on a region with larger deformation, and meanwhile, the deformation thickness compensation amount is increased, so that integral deformation structural compensation is realized.
S102, adding 3-6mm of machining allowance compensation to the tool mounting surface and/or the profile matching surface. In S102, a certain thickness of the metal layer (to be cut off) is reserved on the surface of the tool in the machining process, so that in the subsequent fine treatment process, the superfluous metal on the surface to be machined on the tool is removed by a machining method, and the machining surface with the design requirement is obtained.
For example, the step in S10 may use arc additive manufacturing deformation simulation to predict, so as to obtain a region with weak deformation resistance of the tool and a region needing machining allowance compensation, and then pertinently perform inverse deformation structure compensation and machining allowance compensation. In different examples, arc additive manufacturing tests can also be adopted to obtain a comparative sample of the tool, and then the tool model is corrected according to the actual condition of the comparative sample.
S20, layering slicing and path planning processing are conducted on the tooling model. In step S20, based on the obtained tooling model, an adaptation process is performed on the tooling model, so that the arc additive manufacturing equipment can perform an arc additive manufacturing process based on the tooling model, and a tooling is obtained.
Specifically, S20 may specifically include the following steps:
s201, carrying out layering slicing processing on the tool model. In S201, the tooling model is sliced in layers to obtain shape and size information of each layer, and based on the information, the subsequent arc additive manufacturing process is facilitated.
S202, planning a path in the process of forming the tool based on the tool model. In S202, a path plan is set to implement an arc additive manufacturing operation and improve manufacturing efficiency in an arc additive process. Illustratively, as shown in fig. 3, when path planning is performed, paths can be filled along parallel lines of the short sides of the tooling model in a reciprocating manner, so that residual stress and deformation formed by additive manufacturing can be reduced, and the surface quality of the tooling for arc additive manufacturing can be improved. When the parallel line filling paths are reciprocated along the short sides of the tooling model, the short sides of the tooling model refer to the reciprocating filling paths according to the length, the width and the height of the tooling model by taking the tooling model as a basis, wherein the side with smaller slice pattern size is subjected to the reciprocating filling paths, and the adjacent paths are arranged in parallel (except for connecting lines of the adjacent paths).
In S20, the order of S201 and S202 is not sequential. For example, the compensated tooling model may be converted into a software format, and then the tooling model may be subjected to hierarchical slicing and path planning by specific software, such as BP software.
S30, manufacturing and forming the tool by using the arc fuse additive. In S30, specific parameters are input into the arc additive manufacturing apparatus based on the layering slice information and path planning of the tooling, and when tooling manufacturing is required, operation processing is performed by the arc additive manufacturing apparatus.
Specifically, S30 may include the following steps:
S301, selecting a substrate. In S301, a substrate is selected to support the molding of the tooling. In particular and examples, the substrate periphery may be secured to a base of the arc additive manufacturing apparatus by bolts. In some of these examples, the substrate material used for the additive forming may be a stainless steel substrate or a structural steel substrate, such as ER304 stainless steel, invar36 steel wire, wire diameter phi = 1.0-1.2mm. In other examples, the thickness of the substrate may be 30-50mm.
S302, injecting protective gas into the tool forming working cavity. In S302, a shielding gas is used to protect the arc additive manufacturing. By using the mixed gas of 85% Ar+15% CO2 as the shielding gas, the stability of the welding process can be effectively improved, the splashing can be reduced, and the welding quality can be improved.
S303, setting all technological parameters of tool molding. In S303, manufacturing of the tooling is achieved by setting process parameters. Illustratively, the process parameters may be set as follows: layering slice thickness l=2-5 mm, wire feed speed V f =6.5-7.5 m/min, current i=115-135A, voltage u=13-18V, forming speed vw=10-15 mm/s, forming pitch h=1.8-3.0 mm. It should be noted that some or all of these settings may be used, as well as additional process parameters. In some examples, after each layer of additive forming is finished, the welding gun lifts the height l of the slice layer thickness, and the starting point of arc additive forming is randomly changed, so that the dimensional deviation caused by fixed-position arcing can be reduced. In other examples, the interlayer temperature of the tooling forming can be between 150 and 200 ℃, compressed air can be used between the layers to cool the additive forming tooling structure, and the situation that grains are coarse caused by multi-layer temperature accumulation can be effectively reduced through the arrangement in the example.
In S30, the steps of S301, S302 and S303 are partially followed, and the corresponding operation steps may be separately completed.
S40, performing heat treatment on the molded tooling blank with the substrate. In S40, by performing heat treatment on the tool blank, the non-uniformity of the structure and performance formed by arc additive manufacturing can be further reduced, and the service performance of the tool is improved. In the heat treatment process, the tooling blank is still connected with the substrate, the substrate is not treated at this time, and the tooling blank connected with the substrate is subjected to heat treatment. Illustratively, after the arc additive manufacturing process is completed, the resulting tooling may employ a destressing annealing heat treatment and a solution heat treatment: the solid solution temperature can be 1000-1060 ℃, the heat treatment time can be 4-6h, and then the mixture is cooled to room temperature.
S50, carrying out secondary processing on the tool blank subjected to heat treatment to obtain a tool finished product.
Wherein, S50 specifically includes the following steps:
S501, cutting off a substrate connected with the tooling blank. In S501, after the tooling blank is heat treated, the structure is relatively stable, and at this time, the connected substrate is cut off. For example, wire cutting may be used to switch the excess substrate.
S502, structure processing. In 502, the tooling structure is machined according to the digital-analog and precision control requirements of the complex curved tooling structure. Illustratively, the excess material of the mounting location holes, the profile mating surfaces and the like can be removed, and the machining precision is controlled to be +/-0.05 mm.
In S50, the order of S501 and S502 is not sequential.
S60, detecting the size of the finished product of the tool. The formed tool finished product can meet the requirements, and the tool finished product which does not meet the requirements can be returned to the previous step for corresponding treatment or recovery, and is subjected to subsequent centralized treatment.
Specifically, S60 may specifically include the following steps:
s601, detecting the inside of a finished product of the tool. For example, one or more of ultrasonic flaw detection and X-ray nondestructive detection can be adopted, and whether defects such as unfused, air holes, cracks and the like exist in the finished product of the tool or not can be detected.
S602, air tightness detection is carried out.
S603, detecting the structural size of the finished tool product. For example, the structural size of the finished product of the tool can be detected through three coordinates.
The foregoing description is only a preferred embodiment of the present invention, and is not intended to limit the present invention in any way, and any simple modification, equivalent variation, etc. of the above embodiment according to the technical matter of the present invention fall within the scope of the present invention.
Claims (10)
1. The arc additive manufacturing method of the complex curved surface tooling structure of the composite material is characterized by comprising the following steps of:
layering and slicing the tooling model based on the tooling model;
planning a path of the tool molding; the method comprises the steps of filling paths along parallel lines of a short side of a tooling model in a reciprocating manner during path planning;
and carrying out tooling forming based on the layering slice information and the path planning information.
2. The method for manufacturing the arc additive of the complex curved surface tooling structure of the composite material according to claim 1, wherein the tooling forming based on the layering slice information and the filling path comprises:
Selecting a substrate;
injecting protective gas into the tool forming working cavity;
Setting technological parameters for tooling forming;
and (5) performing tooling forming to obtain a tooling blank.
3. The method for manufacturing the arc additive of the complex curved surface tooling structure of the composite material according to claim 2, wherein the thickness of the selected substrate is 30-50mm.
4. The method for manufacturing the arc additive of the complex curved surface tooling structure of the composite material according to claim 2, wherein the injected shielding gas is a mixed gas of 85% Ar+15% CO 2.
5. The arc additive manufacturing method of the complex curved surface tooling structure of the composite material according to claim 2, wherein the technological parameters used for tooling forming comprise: layering slice thickness l=2-5 mm, wire feed speed V f =6.5-7.5 m/min, current i=115-135A, voltage u=13-18V, forming speed vw=10-15 mm/s, forming pitch h=1.8-3.0 mm.
6. The method for manufacturing the arc additive of the complex curved surface tooling structure of the composite material according to claim 2, wherein the temperature between the tooling forming layers is 150-200 ℃.
7. The arc additive manufacturing method of the complex curved surface tooling structure of the composite material according to claim 2, wherein after tooling forming, the tooling blank is obtained, further comprising the steps of:
Carrying out heat treatment on the tooling blank with the substrate, and comprising: the solid solution temperature is 1000-1060 ℃, the heat treatment time is 4-6h, and the mixture is cooled to room temperature.
8. The method of arc additive manufacturing of complex curved tooling structure of composite material of claim 7, further comprising the steps of, after heat treating the tooling blank with the substrate: and taking out the redundant substrate by adopting linear cutting to obtain a finished product of the tool.
9. The arc additive manufacturing method of the complex curved surface tooling structure of the composite material according to claim 8, wherein the method is characterized in that the wire cutting is adopted to take out the redundant substrate, and after the tooling finished product is obtained, the method further comprises the following steps:
Detect frock finished product, include:
Carrying out ultrasonic flaw detection and/or X-ray nondestructive detection on the structure of the finished product of the processed tool;
Air tightness detection is carried out;
And detecting the structural size of the finished product of the tool by adopting three coordinates.
10. The arc additive manufacturing method of the composite material complex curved surface tooling structure according to claim 1, further comprising the following steps before layering and slicing the model based on the tooling model:
The method for obtaining the tooling model specifically comprises the following steps:
in the preparation process of the tooling model, carrying out integral inverse deformation structure compensation on the area with the deformation of the tooling model being more than 10-15%;
And adding 3-6mm of machining allowance compensation to the tool mounting surface and/or the profile matching surface.
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| US20240286352A1 (en) * | 2023-02-27 | 2024-08-29 | Textron Aviation Inc. | 3D Printer Bed |
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| US20240286352A1 (en) * | 2023-02-27 | 2024-08-29 | Textron Aviation Inc. | 3D Printer Bed |
| US12479160B2 (en) * | 2023-02-27 | 2025-11-25 | Textron Innovations Inc. | 3D printer bed |
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