WO2024226912A1 - Methods for manufacturing vehicle components and vehicle component - Google Patents

Abstract

Systems and techniques for manufacturing vehicle components include forming a plate to have an isogrid pattern with isogrid chambers, the plate having a first shape, manipulating the plate from the first shape to a second shape using a first explosive tooling process, and manipulating the plate from the second shape to a molded blank using a second explosive tooling process. Systems and techniques for manufacturing vehicle components include forming a plate to have an isogrid pattern and having a first shape, manipulating the plate from the first shape to a blank having a second shape, transforming the blank into a semi-molded blank, and applying an explosive tooling process to the semi-molded blank to form a molded blank.

Description

METHODS AND APPARATUS FOR MANUFACTURING VEHICLE COMPONENTS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63/498,713 filed April 27, 2023 and U.S. Provisional Application No. 63/509,429 filed June 21 , 2023, the entireties of each of which is incorporated by reference herein.

TECHNICAL FIELD

[0002] Aspects of the present disclosure generally relate to manufacturing vehicle components and, more specifically, to design and manufacturing of vehicle surface features such as by using high energy hydro forming (e.g., explosive tooling).

BACKGROUND OF THE INVENTION

[0003] Vehicle components such as a frames, fuselage, wings, monocoques, empennages, booms, leading and trailing edges, and/or the like are traditionally manufactured using a base structure that supports and is attached to an overlay skin. Such a process requires joining multiple individually manufactured subcomponents and attaching the overlay skin to such joined sub-components. However, such a process is resource intensive and can lead to defects introduced during the joining of parts and/or attaching of the overlay skin.

[0004] The present disclosure is accordingly directed to manufacturing vehicle components using a plate (e.g., a sheet, a piece, a layer, etc.) and/or a high energy hydro forming process. The background description provided herein is for the purpose of generally presenting the context of the disclosure. Unless otherwise indicated herein, the materials described in this section are not prior art to the claims in this application and are not admitted to be prior art, or suggestions of the prior art, by inclusion in this section.

SUMMARY OF THE DISCLOSURE

[0005] Aspects of the subject matter disclosed herein are related to a method for manufacturing vehicle components including forming a plate to have an isogrid pattern with isogrid chambers, the plate having a first shape, manipulating the plate from the first shape to a second shape using a first explosive tooling process; and manipulating the plate from the second shape to a molded blank using a second explosive tooling process.

[0006] The method further includes filling an isogrid chamber of the isogrid chambers with a temporary filler before manipulating the plate from the first shape to the second shape, removing the temporary filler from the isogrid chamber after manipulating the plate from the second shape to the molded blank wherein removing the temporary filler from the isogrid chamber comprises applying a simple solvent to the temporary filler. The first explosive tooling process is performed using a first progressive plate and a second progressive plate, and the second explosive tooling process is performed using the first progressive plate after removing the second progressive plate. The first explosive tooling process is performed using a first progressive plate, and the second explosive tooling process is performed using a second progressive plate after removing the first progressive plate. The molded blank is a mirror component. Forming the plate to have the isogrid pattern includes scoring the plate to form the isogrid pattern. One of the isogrid pattern or a thickness of the plate is output by a properties machine learning model. The plate includes at least one of aluminum, copper, titanium, steel, stainless steel, magnesium, or an alloy thereof. The isogrid pattern includes one of a vehicle component shape, a pattern, a grid, a rectangular shape, a circular shape, or a diamond shape.

[0007] Aspects of the subject matter disclosed herein are related to a vehicle component of a vehicle formed by a process including forming a plate to have an isogrid pattern with isogrid chambers, the plate having a first shape, manipulating the plate from the first shape to a second shape using a first explosive tooling process; and manipulating the plate from the second shape to a molded blank using a second explosive tooling process.

[0008] The process further includes filling an isogrid chamber of the isogrid chambers with a temporary filler before manipulating the plate from the first shape to the second shape. The first explosive tooling process is performed using a first progressive plate and a second progressive plate, and the second explosive tooling process is performed using the first progressive plate after removing the second progressive plate. The first explosive tooling process is performed using a first progressive plate, and the second explosive tooling process is performed using a second progressive plate after removing the first progressive plate. [0009] Aspects of the subject matter disclosed herein are related to a method for manufacturing vehicle components including forming a plate to have an isogrid pattern, the plate having a first shape, manipulating the plate from the first shape to a blank having a second shape, transforming the blank into a semi-molded blank, and applying an explosive tooling process to the semi-molded blank to form a molded blank.

[0010] The method further includes forming the plate includes joining two or more plates using a friction stir welding (FSW) process, applying a thermal metallurgical cycle to the semi-molded blank, wherein manipulating the plate includes applying a force to one or more areas of the plate, wherein the force causes the first shape of the plate to physically change, wherein manipulating the plate includes supporting the plate using a support structure during a friction stir welding (FSW) process, wherein transforming the blank into a semi-molded blank includes positioning a first end of the blank at a female tool, and applying a force via a male punch at a second end of the blank different than the first end, wherein the force causes a physical property of the blank to change. One of a shape of the female tool or a shape of the male punch is output by a tooling machine learning model. Transforming the blank into a semi-molded blank includes: positioning a first end of the blank at a female tool, applying a first force via a first male punch at a second end of the blank different than the first end, wherein the first force causes a first physical property of the blank to change by a first amount; and applying a second force via a second male punch at the second end of the blank, wherein the second force causes a second physical property of the blank to change by a second amount. Applying the explosive tooling process includes, placing the semi-molded blank in a female chamber, immersing the semi-molded blank in the female chamber in a fluid; and performing a controlled explosion within the female chamber, wherein the controlled explosion causes a shape of the molded blank to change. Applying the explosive tooling process includes constraining a portion of the semi-molded blank to a female chamber.

[0011] The above summary is not intended to describe each and every embodiment or implementation of the present disclosure

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate the disclosed embodiments, and together with the description, serve to explain the principles of the disclosed embodiments. There are many aspects and embodiments described herein. Those of ordinary skill in the art will readily recognize that the features of a particular aspect or embodiment may be used in conjunction with the features of any or all of the other aspects or embodiments described in this disclosure. In the drawings:

[0013] Figure 1 depicts structural components of a vehicle, according to various aspects of the present disclosure.

[0014] Figure 2A depicts a plate having an isogrid surface, according to various aspects of the present disclosure.

[0015] Figure 2B depicts a sectional side view of the plate of Figure 2A having the isogrid surface, according to various aspects of the present disclosure.

[0016] Figure 3 depicts manipulation of the plate of Figure 2A, according to various aspects of the present disclosure.

[0017] Figure 4 depicts a side view of further manipulation of the plate of Figures 2 and 3, according to various aspects of the present disclosure.

[0018] Figure 5 depicts tools based blank manipulation, according to various aspects of the present disclosure.

[0019] Figure 6 depicts a semi-molded blank having excess material, according to various aspects of the present disclosure.

[0020] Figure 7 depicts a molded blank after an explosive tooling process, according to various aspects of the present disclosure.

[0021] Figure 8 is a flowchart for manufacturing a molded blank, according to various aspects of the present disclosure.

[0022] Figure 9A depicts a prospective view of components for performing an explosive tooling processes, in accordance with aspects of the present disclosure.

[0023] Figure 9B depicts a side sectional view of components for performing an explosive tooling processes, in accordance with aspects of the present disclosure.

[0024] Figure 10 is another flow diagram for manufacturing a molded blank, in accordance with aspects of the present disclosure.

[0025] Figure 11 is a flow diagram for training a machine learning model, in accordance with aspects of the present disclosure.

[0026] Figure 12 is an example computing environment, in accordance with aspects of the present disclosure. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0027] Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed. As used herein, the terms “comprises,” “comprising,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus. Additionally, the term “exemplary” is used herein in the sense of “example,” rather than “ideal.” It should be noted that all numeric values disclosed or claimed herein (including all disclosed values, limits, and ranges) may have a variation of +/- 10% (unless a different variation is specified) from the disclosed numeric value. Moreover, in the claims, values, limits, and/or ranges mean the value, limit, and/or range +/-10%.

[0028] Reference will now be made in detail to the exemplary embodiments of the present disclosure described below and illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to same or like parts.

[0029] Additional objects and advantages of the embodiments will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the embodiments. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the claims.

[0030] Conventional component manufacturing (e.g., vehicle component manufacturing) is implemented using a multistep process. Such a multistep process includes manufacturing sub-components (e.g., sub-structural components, framing components), attaching the sub-components to produce a structural component (e.g., using welding, screws, fasteners, and/or other attaching components). The structural components are attached to other structural components. Subsequently, one or more skins are attached to the structural components (e.g., using welding, screws, fasteners, and/or other attaching components). The one or more skins may include an outer surface facing an exterior of, for example, a vehicle. The one or more skins may include an inner surface facing the structural components. [0031] As a specific example, an aerial device (e.g., airplane) may include a fuselage. The fuselage may be manufactured by first manufacturing sub-frame components (e.g., metal components). Each or a sub-set of the sub-frame components may be attached one or more other sub-frame components to form a fuselage skeleton frame. The fuselage skeleton frame may provide structural stability to the fuselage. One or more skins may be attached to the fuselage skeleton frame. The one or more skins attached to the fuselage skeleton frame may form the fuselage.

[0032] Conventional components for vehicles are shaped and manufactured as sub-components and machined (e.g., attached) to create an integral structure. Conventional composite and metallic forming processes used for fabricating large vehicle skin components (e.g., fuselage, wings, etc.) require extensive tooling and manufacturing steps for fabricating vehicle components.

[0033] Techniques and apparatuses disclosed herein provide vehicle components having a laminar flow surface with minimal subassembly attachments. The vehicle components manufactured in accordance with techniques and apparatuses disclosed herein are formed having an integral structure in-situ during the formation process. For these vehicle components, at least an initial version of an integral structure may be machined-in while a plate is substantially flat (e.g., via the isogrid discussed herein). A final version of the integral structure may be obtained post one or more steps discussed herein such as via thinning and/or forming (e.g., using one or more tools and/or an explosive tooling process). According to an implementation, a given vehicle component may be formed in accordance with techniques disclosed herein without additional machining (e.g., attaching of multiple sub-components). For example, as discussed herein in reference to Figures 6 and 7, a given molded component may include excess material. The excess material may be removed, resulting in a vehicle component without additional machining.

[0034] According to implementations disclosed herein, a laminar flow surface quality vehicle using large skin sub-craft components may be manufactured having minimal external joints. The large skin sub-craft components may be joined using friction stir welds or bonding to attach one or more large skin sub-craft components. For example, bonding may be used to add features (e.g., non-structural features, additions, relatively small components relative to a given component, etc.) to a vehicle component (e.g., fuselage, wing, monocoques, empennages, booms, leading and trailing edges, etc.). Techniques and apparatus disclosed herein facilitate manufacturing entire or substantial portions of vehicle components (e.g., fuselage, wing, monocoques, empennages, booms, leading and trailing edges, etc.) with minimal manufacturing labor (e.g., touch labor, joining labor, positioning labor, etc.) and time and using traditional forming practices with timely incorporation of metallurgical thermal processing and/or explosive forming technology (e.g., explosive tooling, as discussed herein).

[0035] Techniques and apparatus disclosed herein are directed to build-up integral skins formed using friction stir welding or bonding in-situ with manufacturing so that a resulting formed component requires minimal additional structural assembly. Blanks thicknesses provide machined integral structures (e.g., with required structural integrity) in-situ with manufacturing so that the resulting formed components require minimum additional structural assembly. Blank thicknesses are determined (e.g., by a machine learning model) to provide a machined integral structure in-situ with build-up integral skins using friction stir welding or bonding and in-situ with manufacturing. Accordingly, the resulting formed feature needs minimum additional structural assembly. Forming mirrored details as one manufacturing process using the techniques disclosed herein may minimize time and/or resources required such as manufacturing tooling, steps, and/or costs.

[0036] High energy hydropress forming (explosive tooling) may be applied to fabricate vehicle components (e.g., large vehicle components) using reduced manufacturing steps and costs. These large components may be manufactured as full size components or substantially full sized components, requiring fewer overall components (e.g., sub-components) to fabricate vehicles (e.g., land vehicles, water vehicles, air vehicles, space vehicles, etc.). A sub-component may be, for example, a framing component, a skin, and/or the like that are manufactured separately and joined together. Where limited by raw material blank or plate size, plates (e.g., sheets, pieces, layers, etc.) can be joined together to create large blanks using friction stir welding (FSW) to support the manufacturing of full-size or substantially full-size components. An FSW process may be tailored to subsequently support a follow-on forming and as needed thermal cycling to complete the manufacturing process. These welds may be capable of ‘fly-away’ loads and properties.

[0037] Manufacturing in accordance with the techniques disclosed herein may benefit from superior part integrity and structural properties by using a plate (e.g., a sheet, a piece, a layer, etc.) having an isogrid process. The process may use a heat treated fluid (e.g., as discussed in reference to Figure 7 here) and explosive tooling process to eliminate or mitigate the need to handwork formed parts (e.g., if manufacturing started in a pre-solution, annealed, or F-condition). The forming may include an applicable count of FSW to hold an amount of blank needed to fabricate the vehicle components, as discussed herein. FSW may be used to supplement forming operations using tooling and/or presses to form the full-size feature.

[0038] Application of additional components to a formed blank (e.g, stiffeners, stringers, frames, etc.) may be strategically performed using joining such as FSW, gas tungsten arc welding, bonding and/or fastening. When machining, aging, and/or subsequent explosive forming is completed, the resulting component(s) may be within design tolerances, have an extended laminar flow surface, and may be manufactured based on reduced manufacturing steps. The processes disclosed herein may be refined to develop manufacturing tooling that accounts for net part or material overages (e.g., spring back).

[0039] Components manufactured in accordance with the techniques disclosed herein may be manufactured prior to fabrication completion of vehicle components. Techniques disclosed herein may be implemented by starting with thicker blanks (e.g., using thicker plates) that undergo machining steps to remove excess material (e.g., aluminum) to form components (e.g., stiffener, stringer, frame, etc.) needed to complete a given feature. Subsequently, aging and/or subsequent explosive tooling may be completed and resulting components may be within tolerance design, have an extended laminar flow surface, and may be manufactured based on reduced manufacturing steps.

[0040] The blank thicknesses discussed herein provide for machined integral structures that may be used during in-situ build-up of integral vehicle features (e.g., stringers, stiffeners, and/or frames) and friction stir welding needed to complete vehicle components. Subsequent in-situ manufacturing, aging, and/or subsequent explosive forming may result in vehicle components within design tolerances that provide for an extended laminar flow surface and may be manufactured based on reduced manufacturing steps.

[0041] Techniques disclosed herein include manufacturing vehicle components (e.g., entire fuselage, wing, monocoques, empennages, booms, etc.) with minimal required manufacturing labor and/or time and may be implemented using explosive tooling. Techniques disclosed herein optimize manufacturing, to a minimal count of steps/details required for fabricating vehicle components. For example, mirror image components may be formed together as one global component. Such mirror image components may be trimmed to remove excessive material, resulting in components within design tolerances, having an extended laminar flow surface length, and may be manufactured based on reduced manufacturing steps.

[0042] According to implementations, techniques disclosed herein include fabricating some, most, or all craft large outer skin structure using explosive tooling tank facilities. Moving leading and trailing edge wing and/or empennage structures may be manufactured in accordance with the techniques disclosed herein. Space bound components designed of stainless, titanium, nickel, aluminum, and/or similar metal systems may be manufactured using techniques disclosed herein to fabricate components with extended length laminar flow surfaces, using as needed fly-away friction stir welds. Techniques disclosed herein may be used to facilitate manufacturing earth-moving equipment (e.g., corresponding large sweeping surfaces), helicopters, flying taxis, cars, and/or other vehicles.

[0043] Figure 1 depicts structural components of a vehicle 102, according to various aspects of the present disclosure. Although an aerial vehicle is shown in Figure 1 and generally discussed herein, it will be understood that the techniques disclosed herein may be used to manufacturer any applicable vehicle components including, but not limited to, land vehicles, water vehicles, aerial vehicles, space vehicles, equipment, etc. Techniques disclosed herein may be used to manufacture one or more vehicle components shown in Figure 1 .

[0044] Techniques and apparatuses disclosed herein may be used to manufacture vehicle components including, but not limited to, components 102A, 102B, 102C, 102D, and/or 102E, as shown in Figure 1. Component 102A may be a fuselage and may be, for example, approximately twenty-one feet in length. Component 102B may be a wing and may be, for example, approximately thirty-four feet in length. Component 102C may be a second fuselage and may be, for example, approximately twenty-one feet in length. Components 102A, 102B, 102C, 102D, and/or 102E may be manufactured to include a laminar flow surface (e.g., a component having one or more laminar flow outer mole line surfaces) and structural integrity and may not require manufacturing sub-components such as a frame and a skin and thereafter joining the sub-sub components and/or skin. Rather, as further discussed herein, components (e.g., components 102A, 102B, 102C, 102D, and/or 102E) may be manufactured using a plate (e.g., a sheet, a piece, a layer, etc.) having an isogrid surface that is transformed into a vehicle component (or portions thereof) having a laminar flow surface. The manufactured vehicle components may provide structural integrity (e.g., without a frame) and the laminar flow surface.

[0045] Figure 2A depicts a plate 202 (e.g., a sheet, a piece, a layer, etc.) having an isogrid surface 204, according to various aspects of the present disclosure. Plate 202 may include a metallic material (e.g., aluminum, copper, titanium, steel, stainless steel, magnesium, etc.), an alloy thereof, or the like, or a combination thereof. Plate 202 may be formed from multiple plates. For example, two or more plates may be joined together (e.g., using FSW) to form plate 202. The two or more plates may be dimensioned such that joining the two or more plates may result in plate 202 having requisite dimensions. Plate 202 and/or the two or more plates joined to form plate 202 may include excess material which may be removed.

[0046] An FSW process, as discussed herein, may include a solid-state joining process that uses a non-consumable tool to join two facing components (e.g., without melting component material). Heat may be generated based on friction between a FSW tool (e.g., a rotating tool) and the component material(s), which may lead to a softened region near the FSW tool. The FSW tool may be traversed along a joint line created at the facing components, may mechanically intermix the material of the facing components, and may forge the hot/softened material (e.g., metal) by mechanical pressure applied by the FSW tool.

[0047] Plate 202 may have a uniform thickness or a variable thickness. The thickness may range from approximately 0.1 inches to 1.5 inches. Isogrid surface 204 may be formed on a first surface of plate 202. Isogrid surface 204 may include a partially hollowed-out structure formed from plate 202 and may include any applicable shapes such as shapes corresponding to vehicle components, patterns, grids, rectangular shapes, circular shapes, diamond shapes, etc.

[0048] The uniform thickness or variable thicknesses of plate 202 may be determined based on a target molded blank (e.g., as further discussed in reference to Figure 7). The target molded blank may be a vehicle component or part of a vehicle component formed in accordance with the techniques disclosed herein. The uniform thickness or variable thicknesses of plate 202 may be determined such that, after completion of the techniques disclosed herein, the target molded blank has target properties such as a target shape, target dimensions, target structural integrity, target laminar flow, and/or the like. Accordingly, the uniform thickness or variable thicknesses of plate 202 may be pre-determined such that after plate 202 undergoes the techniques disclosed herein, the resulting target molded blank has the target properties.

[0049] Similarly, properties of isogrid surface 204 may be determined based on the target molded blank (e.g., as further discussed in reference to Figure 7). The properties of isogrid surface 204 may include an isogrid shape, isogrid dimensions, isogrid orientation, isogrid thicknesses, etc. The properties of isogrid surface 204 may be determined such that, after completion of the techniques disclosed herein, the target molded blank has target properties such as a target shape, target dimensions, target structural integrity, target laminar flow, and/or the like. Accordingly, the properties of isogrid surface 204 may be pre-determined such that after plate 202 having isogrid surface 204 undergoes the techniques disclosed herein, the manufactured target molded blank has the target properties.

[0050] The uniform thickness or variable thicknesses of plate 202 and/or properties of isogrid surface 204 may be output by a properties machine learning model. The properties machine learning model may be trained based on historical or simulated target molded blank properties, historical or simulated plate thicknesses, historical or simulated isogrid surface properties, and/or the like. The properties machine learning model may be trained to output plate thicknesses and/or isogrid surface properties based on a target molded blank and respective target molded blank properties. The properties machine learning model may be refined (e.g., retrained) based on one or more iterations of manufacturing a molded blank based on initial plate thicknesses and/or isogrid surface properties or based on one or more previous properties machine learning model outputs of plate thicknesses and/or isogrid surface properties. For example, a first molded blank may be generated in accordance with the techniques disclosed herein. One or more properties (e.g., shape, dimensions, thicknesses, etc.) of the molded blank may require adjustment. The adjustments may be provided to the properties machine learning model as training data. The properties machine learning model may be re-trained based on the adjustments such that a subsequent iteration of the properties machine learning model is configured to output updated plate thicknesses and/or isogrid surface properties in view of the adjustments.

[0051] Figure 2B depicts a sectional side view of plate 202 of Figure 2A having the isogrid surface 204. As shown in Figure 2B, forming the isogrid surface 204 may include forming isogrid chambers 206 by hollowing out or removing material from plate 202. As further discussed herein, isogrid chambers 206 may be formed by scoring plate 202 to remove material from plate 202. It will be understood that Figure 2B depicts an example portion of plate 202. It will also be understood that although rectangular shaped isogrid chambers 206 are shown in Figure 2B, isogrid chambers 206 may have any applicable shape such as, for example, shapes corresponding to vehicle components, patterns, grids, symmetric shapes, asymmetric shapes, circular shapes, diamond shapes, etc. As shown in Figure 2B, the shape of isogrid chambers 206 may defined by one or more boundaries of isogrid surface 204, which may be formed by portions of plate 202 that are not hollowed out or otherwise removed.

[0052] According to embodiments of the disclosed subject matter, a temporary filler 208 may be applied to fill one or more isogrid chambers 206. Temporary filler 208 may be used to fill the one or more isogrid chambers 206 after the isogrid surface 204 is formed (e.g., by hollowing out plate 202 to form isogrid surface 204). Temporary filler 208 may be inserted into the one or more isogrid chambers 206 using any applicable process such as an injection process, a press process (e.g., by overlaying temporary filler 208 over plate 202 and applying pressure over temporary filler 208 in the direction of plate 202), a pour process, and/or the like. Temporary filler 208 may provide structural integrity to plate 202 such that plate 202 is not punctured, broken, cracked, damaged, or otherwise unintentionally modified during one or more molding processes discussed herein. Temporary filler 208 may be any applicable material that provides structural integrity to plate 202 having isogrid surface 204 during such molding processes. For example, temporary filler 208 may be a non-water soluble material such as a rubber material, a potting material, a polymer, a plaster, and/or the like. As further discussed herein, after the one or more molding processes to form a molded blank from plate 202, temporary filler 208 may be removed from plate 202. The removal may be performed by applying a solvent (e.g., simple solvent) that dissolves temporary filler 208. Alternatively, or in addition, temporary filler 208 may be removed using a scooping or picking process to extract temporary filler 208 from plate 202. [0053] Figure 3 depicts manipulation of the plate 202 of Figure 2A, according to various aspects of the present disclosure. As shown, plate 202A may be an intermediate manipulated version of plate 202. Plate 202A and may have the isogrid surface 204 (not shown in Figure 3) at a first surface of plate 202A. Plate 202 of Figure 2A may be manipulated such that a shape of plate 202 changes from a first shape (as shown via plate 202 in Figure 2A) to a second shape (as shown via plate 202B in Figure 3), where plate 202A shows plate 202 in an intermediate shape. The second shape (plate 202B of Figure 3) may be determined based on a target (e.g., intended) molded blank associated with plate 202 (as further discussed in Figure 7), and may be output by a machine learning model (e.g., the properties machine learning model discussed herein or a different machine learning model). As shown in Figure 2A, plate 202A may be manipulated using one or more roll panels 302A, 302B, 302C such that one or more roll panels 302A are positioned at the first surface of plate 202A and one or more other roll panels 302B, 302C are positioned on a second (e.g., opposing) surface of plate 202A. Although manipulation of plate 202 is conducted using roll panels 302A, 302B, 302C as shown in Figure 3, it will be understood that plate 202 may be manipulated using any applicable technique such as a force based technique, a friction based technique, etc. Manipulation of plate 202 may include applying a force (e.g., using roller panels 302A, 302B, and/or 302C) that causes a shape of the plate to physically change.

[0054] Figure 4 depicts a side view of further manipulation of plate 202 shown in Figures 2 and 3, according to various aspects of the present disclosure. Plate 202 may be transformed to a second shape (shown as plate 202 B in Figure 4) where plate 202B may be plate 202 folded over such that it forms a cylindrical, substantially cylindrical, elongated, ribbon, or other applicable shape. As shown in Figure 4, the second shape may include folding areas 406A and 406B where plate 202B folds to form a target mold shape. The second shape may be determined based on the target molded blank associated with plate 202. As shown in Figure 4, plate 202B may be formed over and/or around a support structure 402 (e.g., a table). The support structure 402 may support plate 202B during a FSW process, using an FSW tool 404, implemented to connect portions of plate 202B (e.g., portions of plate 202B facing each other as a result of the plate having the second shape).

[0055] Figure 5 depicts tools based blank manipulation of plate 202, according to various aspects of the present disclosure. The FSW process of Figure 4 may result in a blank 2020 shown in Figure 5. Blank 2020 may be plate 202B of Figure 4 in the second shape and having undergone the FSW process. According to an implementation, blank 2020 may include one more components, such as an additional metal component in addition to plate 202B of Figure 4. For example, blank 2020 may include an underside metal plate (not shown) that may connect edges or two or more surfaces of plate 202B of Figure 4. Accordingly, plate 202B and the additional metal component may form blank 2020.

[0056] Blank 202C may have a shape such that one or more tools may be used to manipulate the blank. As shown in Figure 5, blank 202C may be placed in and/or over a female tool 502. Female tool 502 may be shaped and sized to hold blank 2020 in place while blank 2020 is manipulated using a male punch 504. Female tool 502 may exert a counter force against blank 2020, in response to a force exerted by male punch 504. Accordingly, male punch 504 may apply force to the interior of blank 202C such that blank 202C’s shape and/or thickness is manipulated as a result of the force. Female tool 502 may be shaped to apply the counter force against an outer surface of blank 2020. Male punch 504 may be shaped such that the force applied by male punch 504 manipulates blank 202C via the inner surface of blank 2020, including isogrid surface 204. As a result, blank 2020 and/or isogrid surface 204 may be manipulated such that they are reshaped based on the force exerted by male punch 504. The reshaping may cause blank 202C to have intermediate shapes and/or dimensions (e.g., thicknesses) such that the techniques further discussed herein allow blank 202C to form into the molded blank of figure 7 (e.g., via transformations shown via blank 202C, semi-molded blank 202D, and molded blank 202E).

[0057] According to an implementation, a dampening sheet (e.g., a cloth sheet, a paper sheet, a plastic sheet, etc. or a combination thereof) may be applied between male punch 504 and blank 202C and/or between blank 2020 and female tool 502. The dampening sheet may dampen or otherwise reduce the tool-on-blank friction between these components. Accordingly, the dampening sheet may mitigate or prevent unintended effects of direct contact between male punch 504 and blank 202C and/or between blank 202C and female tool 502.

[0058] Female tool 502 and/or male punch 504 may be modified and/or iteratively replaced such that blank 2020 undergoes multiple iterations of manipulation based on the modified and/or iteratively replaced female tool 502 and/or male punch 504. The multiple iterations may be implemented using one or more female tool 502 adapters and/or male punch 504 adapters. Such adapters may be attached to or otherwise connected to respective female tool 502 and/or male punch 504. For example, a female tool 502 adapter may reduce an opening of female tool 502 to facilitate forming of blank 202C using a male punch 504 adapter. The multiple iterations of manipulation may cause blank 202C to be shaped in accordance with the target molded blank discussed in Figure 7. The result of the iterative process may a semi-molded blank 202D, as shown in Figure 6.

[0059] Female tool 502 and/or male punch 504, and/or any iterations thereof, may have properties output by a tooling machine learning model. Tooling machine learning model may be trained based on historical or simulated target molded blanks, historical or simulated female tools, and/or male punches, and/or the like. The tooling machine learning model may be trained to output tool/punch properties based on a target molded blank and respective target molded blank tooling. The tooling machine learning model may output tool properties (e.g., female tool properties, male punch properties, etc.) based on an output of the properties machine learning model. For example, the properties machine learning model may output plate thicknesses and/or isogrid properties based on a target molded blank. The tooling machine learning model may receive the plate thicknesses and/or isogrid properties and may output tool properties based on the same. The tooling machine learning model may be refined (e.g., re-trained) based on one or more iterations of manufacturing a molded blank based on tool/punch properties or based on one or more previous tooling machine learning model outputs of tool/punch properties.

[0060] Figure 6 depicts semi-molded blank 202D discussed above and having excess material 604, according to various aspects of the present disclosure. Semimolded blank 202D may be formed based on the process discussed in reference to Figure 4. Female tool 502 and/or male punch 504, and any iterations thereof, may be used to form blank 202D from blank 202C of Figure 4.

[0061] Semi-molded blank 202D may include excess material 604 such that excess material 604 is configured to transform to an intended shape based on additional expansion or modification of semi-molded blank 202D (as further discussed in reference to Figure 7). Alternatively or in addition, excess material 604 may be removed from blank 202D, as further discussed herein. [0062] Semi-molded blank 202D may include a surface 602 which may be an edge or periphery surface formed by semi-molded blank 202D. Surface 602 may be an opening that provides access to an interior of semi-molded blank 202D.

[0063] Figure 7 depicts a molded blank 202E after an explosive tooling process is applied to semi-molded blank 202D, according to various aspects of the present disclosure. The explosive tooling process may be implemented in a liquid (e.g., water) filled tank. The explosive tooling process may include or may be performed after securing portions of the semi-molded blank 202D of Figure 6 (e.g., one or more edges) to a female chamber (not shown) that encompasses all or a portion of the semi-molded blank 202D of Figure 6. For example, surface 602 of semi-molded blank 202D may be constrained (e.g., to the female chamber) using an applicable constraining component such as one or more fasteners, joiners, attachments, or the like, or a combination thereof. Constraining semi-molded blank 202D (e.g., at surface 602) may prevent unintended movement of semi-molded blank 202D during the explosive tooling process. Constraining semi-molded blank 202D (e.g., at surface 602) may further facilitate molding of semi-molded blank 202D to produce molded blank 202E, by limiting movement at or near surface 602, thereby facilitating molding at other portions of semi-molded blank 202D.

[0064] Multiple controlled explosions may cause semi-molded blank 202D of Figure 6 to transform into molded blank 202E, as shown in Figure 7. Molded blank 202E may be or may substantially have the shape and/or structural integrity of the intended vehicle component corresponding to molded blank 202E. One or more openings (e.g., formed at surface 602) may be filed using FSW and/or components (e.g., metal components).

[0065] The multiple controlled explosions may cause modifications to semimolded blank 202D, to generate molded blank 202E. For example, as shown in Figure 7, surface 602 may move from a first position of semi-molded blank 202D to a second position indicated by surface 702 of molded blank 202E. Additionally, one or more other surfaces of semi-molded blank 202D may move from a first position of semi-molded blank 202D to a second position indicated by surface 704. In this example, excess material 604 of semi-molded blank 202D may expand to form surface 704.

[0066] The interior of molded blank 202E of Figure 7 may correspond to the interior of the intended vehicle component (e.g., a fuselage). The interior of molded blank 202E may include a version of isogrid surface 204 (a manipulated isogrid surface). The manipulated isogrid surface may be a manipulated during the transformation of plate 202 to a second shape (shown via plate 202B in Figure 3), during the transformation of plate 202B into blank 202C (shown in Figure 4), transforming blank 202C into semi-molded blank 202D (shown in Figures 5 and 6) and/or transforming semi-molded blank 202D into molded blank 202E (shown in Figure 7). The manipulated isogrid surface may form the corresponding vehicle component with a target structural integrity.

[0067] Figure 8 is a flowchart 800 for manufacturing a molded blank (e.g., molded blank 202E of Figure 7). At step 802, a plate (e.g., plate 202 of Figure 2A) may be formed to have an isogrid pattern. The plate may be formed to have a uniform or variable thicknesses. For example, the thicknesses may range from approximately 0.10 inches to approximately 1.50 inches. The plate may be formed by joining two or more plates. The plate may be formed of any applicable material (e.g., aluminum, copper, titanium, steel, stainless steel, magnesium, etc.), an alloy thereof, or the like, or a combination thereof.

[0068] The isogrid pattern may be formed using any applicable technique, such as scoring, and may modify the plate. The scoring may be applied while the plate is flat and/or may be applied while the plate is in a non-flat form (e.g., at steps 804-806, as further discussed herein). The isogrid pattern may be formed by removing material from the plate such that the resulting plate includes the isogrid pattern. The isogrid pattern may include any applicable shape such as shapes corresponding to vehicle components, patterns, grids, rectangular shapes, circular shapes, diamond shapes, etc. Shapes corresponding to vehicle components may be, for example, shapes that define the interior of a corresponding vehicle component. A molded blank manufactured having such shapes (e.g., transformed versions of such shapes post tooling) may meet structural integrity requirements for the corresponding vehicle component, based at least in part on such shapes. As discussed herein, a temporary filler (e.g., temporary filler 208 shown in Figure 2B) may be used to fill isogrid chambers (e.g., isogrid chambers 206 shown in Figure 2B) that form the isogrid pattern.

[0069] At step 804, the plate having the isogrid pattern from step 802 may be manipulated from a first shape to a second shape. Step 804 corresponds to Figures 3-4 discussed herein. The manipulation may include folding the plate from step 802 (e.g., using one or more roll panels) to form a blank (e.g., as shown in Figure 5) having the second shape. According to an embodiment, the manipulation may, for example, result in a blank having a thickness ranging from approximately 0.10 inches to approximately 0.25 inches.

[0070] At step 806, the blank having the second shape may be transformed using one or more of a tool or a punch. A female tool and/or a male punch may be used to apply force against the blank having the second shape to form a semimolded blank (e.g., as shown in Figure 6). Multiple female tools and/or male punches may be iteratively applied to the blank to transform the blank into a molded blank having a target vehicle component shape (e.g., dimensions, thicknesses, properties, etc.). For example, at step 806, the blank may be thinned and/or shaped using one or more female tools and/or male punches to manufacture the molded blank.

[0071] The blank near net shape (e.g., as a result of step 806) may undergo a metallurgical thermal cycle to relieve blank properties, defects, and/or stresses (e.g., to prepare the blank for step 808). The metallurgical thermal cycle may be implemented by changing the temperature of the blank or a certain point of the blank (e.g., edges), over time. The metallurgical thermal cycle may be implemented, for example, using heat generated by a high-frequency welding current or via any applicable heat generating technique. For aluminum, for example, the metallurgical thermal cycle may include exposing a blank or semi-molded blank to temperatures of up to approximately 500 to approximately 700 degrees (e.g., from an ambient or given temperature, incrementally over a period of time). The metallurgical thermal cycle may include exposing a blank or semi-molded blank to such temperatures for a given period of time (e.g., approximately 24 hours, up to approximately 48 hours, etc.). Such exposure may cause a heat-affected zone (HAZ) of the blank or semimolded blank from a T3 zone to a T8 zone and may reduce inherent stresses in a given material, smooth bumps and/or irregularities, improve laminar flow, and/or the like. It will be understood that given temperatures applied during a metallurgical thermal cycle may be determined based on one or more materials of the blank or semi-molded blank.

[0072] At step 808, the semi-molded blank may undergo an explosive tooling process (e.g., as discussed in reference to Figure 7). One or more portions (e.g., surface 602 of Figure 6) of the semi-molded blank may be constrained to a female chamber of an explosive tool such that the semi-molded blank is constrained at the one more portions. The explosive tooling process may include immersing the semimolded blank in a fluid (e.g., a hot fluid, water, etc.) and performing multiple controlled explosions. The multiple controlled explosions may cause the semimolded blank to transform into a molded blank (e.g., as shown in Figure 7). Accordingly, the semi-molded blank shaped at step 806 may be further transformed using an explosive tooling process, to form a vehicle component. The temporary filler (e.g., temporary filler 208 shown in Figure 2B) may be removed from the molded blank in accordance with techniques discussed herein.

[0073] The method described in flowchart 800 may be used for plates having a uniform thickness or a variable thickness. The thickness may range from approximately 0.10 inches to approximately 1.50 inches, as discussed herein. For example, the method described in flowchart 800 and/or Figures 2A-Figure 7 may be applied to plates having a thickness ranging from approximately 0.1 inches to approximately 1 inch.

[0074] Figures 9A and 9B depict another embodiment for forming a molded blank in accordance with the disclosed subject matter. Figure 9A depicts a prospective view of components for application of a progressive explosive tooling processes. Figure 9A includes the plate 202 of Figures 2A and 2B that includes an isogrid surface 204. A part ring 902 may cover at least a portion (e.g., an edge portion) of plate 202. Part ring 902 may be a protective layer that protects plate 202 during one or more progressive explosive tooling processes, as further discussed herein. A securing mechanism 904 (e.g., a clamp, a force fixture, a brace, a clasp, a fastener, etc.) may connect part ring 902 and plate 202 to an explosive forming tool with chamber 906. Figure 9A shows part ring 902 over plate 202 where the securing mechanism 904 connects part ring 902 to an edge of explosive forming tool with chamber 906 such that the edge of plate 202 remains relatively in place in comparison to the rest of plate 202 during one or more progressive explosive forming steps discussed further herein.

[0075] Figure 9B depicts a side sectional view of the components shown in Figure 9A. As shown in Figure 9B, part ring 902 acts as a protective layer over plate 202 and is attached to explosive forming tool with chamber 906 via securing mechanism 904. Plate 202 may be formed into a molded blank (e.g., into molded blank 202E shown in Figure 7) using a series of progressive explosive tooling processes. Each progressive explosive tooling process may be implemented in a liquid (e.g., water) filled tank (e.g., in explosive forming tool with chamber 906). Each progressive explosive tooling process may include or may be performed after securing portions of plate 202 (e.g., one or more edges of plate 202) to explosive forming tool with chamber 906 that encompasses at least a portion of plate 202. For example, as shown in Figure 9B, an edge of plate 202 may be covered by a part ring 902 which may be constrained using securing mechanism 904 to explosive forming tool with chamber 906. Constraining plate 202 may prevent unintended movement of plate 202 during the progressive explosive tooling processes. Constraining plate 202 may further facilitate molding of plate 202 to produce a molded blank (e.g., the molded blank 202E shown in Figure 7) by limiting movement of plate 202 at or near part ring 902, thereby facilitating molding at other portions of plate 202.

[0076] Progressive explosive tooling processes may cause plate 202 of Figure 2A to transform into a molded blank. An example of such progressive explosive tooling processes is depicted in reference to Figure 9B. During a first progressive explosive tooling process, progressive plates 908A, 908B, and 908C may be placed within explosive forming tool with chamber 906. In the example shown in Figure 9B, a surface of progressive plate 908A may face a surface of plate 202 opposite the surface of plate 202 facing part ring 902. The forces generated by one or more controlled explosions proximate to the surface of plate 202 facing part ring 902 may cause portions of plate 202 to mold such that these portions move towards and/or in contact with progressive plate 908A. This process of performing one or more controlled explosions to cause portions of plate 202 to mold towards progressive plate 908A may be considered the first progressive explosive tooling process.

[0077] Subsequent to the first progressive explosive tooling process, progressive plate 908A may be removed such that progressive plates 908B and 908C remain. Accordingly, after removal of progressive plate 908A, a surface of progressive plate 908B may face the molded plate 202 after the first progressive explosive tooling process. As an example, after removal of progressive plate 908A, a space (e.g., a gap) may remain between a surface of molded plate 202 after the first progressive explosive tooling process and progressive plate 908B.

[0078] During a second progressive explosive tooling process, the force generated by one or more controlled explosions proximate to the surface of molded plate 202 after the first progressive explosive tooling process facing part ring 902 may cause portions of this molded plate 202 to further mold such that these portions move towards and/or in contact with progressive plate 908B. This process of performing one or more controlled explosions to cause portions of molded plate 202, after the first progressive tooling process, to mold towards progressive plate 908B may be considered the second progressive explosive tooling process.

[0079] Similarly, subsequent to the second progressive explosive tooling process, progressive plate 908B may be removed such that progressive plates 908C remains. Accordingly, after removal of progressive plate 908B, a surface of progressive plate 908C may face the molded plate 202 after the second progressive explosive tooling process. As an example, after removal of progressive plate 908B, a space (e.g., a gap) may remain between a surface of molded plate 202 after the second progressive explosive tooling process and progressive plate 908C.

[0080] During a third progressive explosive tooling process, the force generated by one or more controlled explosions proximate to the surface of molded plate 202 after the second progressive explosive tooling process facing part ring 902 may cause portions of this molded plate 202 to further mold such that these portions move towards and/or in contact with progressive plate 908C. This process of performing one or more controlled explosions to cause portions of molded plate 202, after the second progressive tooling process, to mold towards progressive plate 908C may be considered the third progressive explosive tooling process.

[0081] According to embodiments, instead of multiple layered progressive plates (e.g., progressive plates 908A, 908B, and 908C of Figure 9B) being placed in and sequentially removed from the explosive tooling chamber 906, single plates may be placed and replaced. For example, during the first progressive explosive tooling process a first single plate (not shown) having a thickness that approximately matches the combined thickness of progressive plates 908A, 908B, and 908C may be placed in the explosive tooling chamber 906. After the first progressive tooling process, the first single plate may be replaced by a second single plate (not shown) having a thickness that approximately matches the combined thickness of progressive plates 908B and 908C may be placed in the explosive tooling chamber 906. The second progressive explosive tooling process may be performed using this second single plate. After the second progressive tooling process, the second single plate may be replaced by progressive plate 908C. The third progressive explosive tooling process may be performed using progressive plate 908C. As shown in Figure 9B, the final progressive plate (e.g., progressive plate 908C) may correspond to a surface of explosive tooling chamber 906.

[0082] It will be understood that although three progressive explosive tooling processes are provided in reference to Figure 9B as an example, any plurality of progressive explosive tooling processes (e.g., greater than one progressive tooling processes) may be performed to transform plate 202 having isogrid surface 204 into a molded blank. It will also be understood the embodiments described in reference to Figures 9A-10 (Figure 10 further discussed below) may be performed using progressive explosive tooling. Such embodiments may be performed without the molding process of Figure 3, the manipulation process of Figure 4, the tools based blank manipulation of Figure 5, and/or the semi-molded blank formation of Figure 6. Rather, the embodiments described in relation to Figures 9A-10 may be used to generate the molded blank depicted in Figure 7 using progressive explosive tooling processes. I will also be understood that according to some other embodiments, one or more of the steps described in reference to Figure 3, Figure 4, Figure 5, and/or Figure 6 may be implemented before or after one or more progressive explosive tooling processes, to generate a molded blank from plate 202.

[0083] Figure 10 is a flowchart 1000 for manufacturing a molded blank. At step 1002, a plate (e.g., plate 202 of Figure 2A) may be formed to have an isogrid surface (e.g., isogrid surface 204 of Figure 2A). The plate may be formed to have a uniform or variable thicknesses. For example, the thicknesses may range from approximately 0.10 inches to approximately 1.50 inches or more specifically, for example, from approximately 0.25 inches to approximately 1.50 inches. The plate may be formed by joining two or more plates. The plate may be formed of any applicable material (e.g., aluminum, copper, titanium, steel, stainless steel, magnesium, etc.), an alloy thereof, or the like, or a combination thereof.

[0084] The isogrid pattern may be formed using any applicable technique, such as scoring, and may modify the plate. The scoring may be applied while the plate is flat and/or may be applied while the plate is in a non-flat form. The isogrid pattern may be formed by removing material from the plate such that the resulting plate includes the isogrid pattern. The isogrid pattern may include any applicable shape such as shapes corresponding to vehicle components, patterns, grids, rectangular shapes, circular shapes, diamond shapes, symmetric shapes, asymmetric shapes, etc. Shapes corresponding to vehicle components may be, for example, shapes that define the interior of a corresponding vehicle component. A molded blank manufactured having such shapes (e.g., transformed versions of such shapes post progressive explosive tooling processes) may meet structural integrity requirements for the corresponding vehicle component, based at least in part on such shapes. As discussed herein, a temporary filler (e.g., temporary filler 208 shown in Figure 2B) may be used to fill isogrid chambers (e.g., isogrid chambers 206 shown in Figure 2B) that form the isogrid pattern.

[0085] At step 1004, the plate having the isogrid pattern from step 1002 may be manipulated from a first shape to a second shape using a first explosive tooling process. Step 1004 is described as the first progressive exploding process in relation to Figure 9B herein. The first progressive exploding process may be implemented using a first progressive plate or multiple progressive plates (e.g., a first and second progressive plates), as discussed herein. The result of the first progressive exploding process may be the plate (e.g., plate 202 of Figure 2A) having the second shape.

[0086] At step 1006, the plate having the second shape from step 1004 may be further manipulated from the second shape to the molded blank using a second explosive tooling process. Step 1006 is described as the third progressive exploding process in relation to Figure 9B herein. The second progressive exploding process may be implemented using a second progressive plate, as discussed herein. The result of the second progressive exploding process may be the molded blank. The temporary filler (e.g., temporary filler 208 shown in Figure 2B) may be removed from the molded blank in accordance with techniques discussed herein.

[0087] The interior of a molded blank formed in accordance with the embodiments described in relation to Figures 9A-10 may correspond to the interior of the intended vehicle component (e.g., a fuselage) discussed herein. The interior of such a molded blank may include a version of isogrid surface 204 (a manipulated isogrid surface). The manipulated isogrid surface may be a manipulated during the transformation of plate 202 during the progressive explosive tooling processes. The manipulated isogrid surface may form the corresponding vehicle component with a target structural integrity.

[0088] The exterior surface of molded blank 202E of Figure 7 or a molded blank formed in accordance with Figures 9A-10 may be a laminar flow surface such that no additional skin is required to generate the intended vehicle component. For example molded blank 202E and or a molded blank formed in accordance with Figures 9A-10 may have one or more laminar flow outer mole line surfaces. For example, such molded blanks and/or semi-molded blanks may include a laminar flow surface with minimal subassembly attachments and/or minimal external attachments. Such molded blanks and/or semi-molded blanks may be configured as components of fly-away vehicles that are configured to fly a threshold distance above a ground surface.

[0089] Such a molded blank may meet structural integrity requirements that may conventionally be provided using sub-components such as framing components. As discussed herein, such a molded blank may be formed to have a laminar flow surface and meet required structural integrity properties using a manufacturing process that does not require joining sub components and/or skins to form a vehicle component. Accordingly, by using plate 202 of Figure 2A and the techniques disclosed herein, vehicle components may be manufactured including a metallurgical thermal cycle in-situ while minimizing manufacturing steps such as connecting sub-components to form a component, without manufacturing and attaching a skin, etc.

[0090] An intended vehicle component manufactured in accordance with the techniques disclosed herein may be a mirror component (e.g., a half) of an overall vehicle component. A mirror component may be a part (e.g., a half) of a corresponding component such that two or more mirror components may be joined to form a full component. A mirror component may be, for example, a top component, a bottom component, a left component, a right component, a diagonal component, or any applicable component that forms a part (e.g., a half) of a full component along a given axis. Accordingly, a first mirrored component may be approximately symmetrical, across a given access, to a second corresponding mirrored component. For example, the techniques disclosed in accordance with Figures 2-10 may be used to generate a first half (e.g., a top half or a left half) of a fuselage at a first time and a second half (e.g., a bottom half or a right half) of the fuselage at a second time. The first half and second half of the fuselage may be mirrored such that they are manufactured using the same process and/or tools. The first half and second half of the fuselage may be joined together to form the fuselage (e.g., using an FSW process).

[0091] One or more implementations disclosed herein may be applied by using a machine learning model (e.g., a tooling machine learning model, a properties machine learning model, etc.). A machine learning model as disclosed herein may be trained using one or more components or steps of Figures 1-10. As shown in flow diagram 1110 of Figure 11 , training data 1112 may include one or more of stage inputs 1114 and known outcomes 1 118 related to a machine learning model to be trained. For example, training data 1112 may include an initial plate, an isogrid pattern, plate material, tool options, etc. The stage inputs 1114 may be from any applicable source including a component or set shown in the figures provided herein. The known outcomes 1 118 may be included for machine learning models generated based on supervised or semi-supervised training. For example, known outcomes 1118 may include a target molded blank, target structural properties, known molded tools, etc. An unsupervised machine learning model might not be trained using known outcomes 1118. Known outcomes 1118 may include known or desired outputs for future inputs similar to or in the same category as stage inputs 1114 that do not have corresponding known outputs.

[0092] The training data 1112 and a training algorithm 1120 may be provided to a training component 1130 that may apply the training data 1112 to the training algorithm 1120 to generate a trained machine learning model 1150. According to an implementation, the training component 1130 may be provided comparison results 11 16 that compare a previous output of the corresponding machine learning model to apply the previous result to re-train the machine learning model. The comparison results 1116 may be used by the training component 1130 to update the corresponding machine learning model. The training algorithm 1120 may utilize machine learning networks and/or models including, but not limited to a deep learning network such as Deep Neural Networks (DNN), Convolutional Neural Networks (CNN), Fully Convolutional Networks (FCN) and Recurrent Neural Networks (RCN), probabilistic models such as Bayesian Networks and Graphical Models, and/or discriminative models such as Decision Forests and maximum margin methods, or the like. The output of the flow diagram 1110 may be a trained machine learning model 1150.

[0093] A machine learning model disclosed herein may be trained by adjusting one or more weights, layers, and/or biases during a training phase. During the training phase, historical or simulated data may be provided as inputs to the model. The model may adjust one or more of its weights, layers, and/or biases based on such historical or simulated information. The adjusted weights, layers, and/or biases may be configured in a production version of the machine learning model (e.g., a trained model) based on the training. Once trained, the machine learning model may output machine learning model outputs in accordance with the subject matter disclosed herein. According to an implementation, one or more machine learning models disclosed herein may generate continuously updated outputs based on feedback associated with use or implementation of the machine learning model outputs.

[0094] It should be understood that embodiments in this disclosure are exemplary only, and that other embodiments may include various combinations of features from other embodiments, as well as additional or fewer features.

[0095] In general, any process or operation discussed in this disclosure that is understood to be computer-implementable, such as the processes illustrated in the flowcharts disclosed herein, may be performed by one or more processors of a computer system, such as any of the systems or devices in the exemplary environments disclosed herein, as described above. For example, a machine learning model disclosed herein may be implemented using a computer system. The computer system may be used to provide inputs, receive outputs, visualize inputs or outputs (e.g., target molded blanks, plate thicknesses, etc.). A process or process step performed by one or more processors may also be referred to as an operation. The one or more processors may be configured to perform such processes by having access to instructions (e.g., software or computer-readable code) that, when executed by the one or more processors, cause the one or more processors to perform the processes. The instructions may be stored in a memory of the computer system. A processor may be a central processing unit (CPU), a graphics processing unit (GPU), or any suitable types of processing unit.

[0096] A computer system, such as a system or device implementing a process or operation in the examples above, may include one or more computing devices, such as one or more of the systems or devices disclosed herein. One or more processors of a computer system may be included in a single computing device or distributed among a plurality of computing devices. A memory of the computer system may include the respective memory of each computing device of the plurality of computing devices.

[0097] Figure 12 is a simplified functional block diagram of a computer 1200 that may be configured as a device for executing the methods disclosed here, according to exemplary embodiments of the present disclosure. For example, the computer 1200 may be configured as a system according to exemplary embodiments of this disclosure. In various embodiments, any of the systems herein may be a computer 1200 including, for example, a data communication interface 1220 for packet data communication. The computer 1200 also may include a central processing unit (“CPU”) 1202, in the form of one or more processors, for executing program instructions. The computer 1200 may include an internal communication bus 1208, and a storage unit 1206 (such as ROM, HDD, SDD, etc.) that may store data on a computer readable medium 1222, although the computer 1200 may receive programming and data via network communications (e.g., via network 100). The computer 1200 may also have a memory 1204 (such as RAM) storing instructions 1224 for executing techniques presented herein, although the instructions 1224 may be stored temporarily or permanently within other modules of computer 1200 (e.g., processor 1202 and/or computer readable medium 1222). The computer 1200 also may include input and output ports 1212 and/or a display 1210 to connect with input and output devices such as keyboards, mice, touchscreens, monitors, displays, etc. The various system functions may be implemented in a distributed fashion on a number of similar platforms, to distribute the processing load. Alternatively, the systems may be implemented by appropriate programming of one computer hardware platform.

[0098] Program aspects of the technology may be thought of as “products” or “articles of manufacture” typically in the form of executable code and/or associated data that is carried on or embodied in a type of machine-readable medium. “Storage” type media include any or all of the tangible memory of the computers, processors or the like, or associated modules thereof, such as various semiconductor memories, tape drives, disk drives and the like, which may provide non-transitory storage at any time for the software programming. All or portions of the software may at times be communicated through the Internet or various other telecommunication networks. Such communications, for example, may enable loading of the software from one computer or processor into another, for example, from a management server or host computer of the mobile communication network into the computer platform of a server and/or from a server to the mobile device. Thus, another type of media that may bear the software elements includes optical, electrical and electromagnetic waves, such as used across physical interfaces between local devices, through wired and optical landline networks and over various air-links. The physical elements that carry such waves, such as wired or wireless links, optical links, or the like, also may be considered as media bearing the software. As used herein, unless restricted to non-transitory, tangible “storage” media, terms such as computer or machine “readable medium” refer to any medium that participates in providing instructions to a processor for execution.

[0099] The many features and advantages of the present disclosure are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the present disclosure that fall within the true spirit and scope of the disclosure. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the present disclosure to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the present disclosure.

[0100] Moreover, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be used as a basis for designing other structures, methods, and systems for carrying out the several purposes of the present disclosure. Accordingly, the claims are not to be considered as limited by the foregoing description.

Claims

CLAIMS What is claimed is:

1 . A method for manufacturing vehicle components comprising: forming a plate to have an isogrid pattern with isogrid chambers, the plate having a first shape; manipulating the plate from the first shape to a second shape using a first explosive tooling process; and manipulating the plate from the second shape to a molded blank using a second explosive tooling process.

2. The method of claim 1 , further comprising filling an isogrid chamber of the isogrid chambers with a temporary filler before manipulating the plate from the first shape to the second shape.

3. The method of claim 2, further comprising removing the temporary filler from the isogrid chamber after manipulating the plate from the second shape to the molded blank.

4. The method of claim 3, wherein removing the temporary filler from the isogrid chamber comprises applying a simple solvent to the temporary filler.

5. The method of claim 1 , wherein, the first explosive tooling process is performed using a first progressive plate and a second progressive plate, and the second explosive tooling process is performed using the first progressive plate after removing the second progressive plate.

6. The method of claim 1 , wherein, the first explosive tooling process is performed using a first progressive plate, and the second explosive tooling process is performed using a second progressive plate after removing the first progressive plate.

7. The method of claim 1 , wherein the molded blank is a mirror component.

8. The method of claim 1 , wherein forming the plate to have the isogrid pattern includes scoring the plate to form the isogrid pattern.

9. The method of claim 1 , wherein one of the isogrid pattern or a thickness of the plate is output by a properties machine learning model.

10. The method of claim 1 , wherein the plate includes at least one of aluminum, copper, titanium, steel, stainless steel, magnesium, or an alloy thereof.

11 . The method of claim 1 , wherein the isogrid pattern includes one of a vehicle component shape, a pattern, a grid, a rectangular shape, a circular shape, or a diamond shape.

12. A vehicle component of a vehicle formed by a process comprising: forming a plate to have an isogrid pattern with isogrid chambers, the plate having a first shape; manipulating the plate from the first shape to a second shape using a first explosive tooling process; and manipulating the plate from the second shape to a molded blank using a second explosive tooling process.

13. The vehicle component of claim 12, wherein the process further comprises filling an isogrid chamber of the isogrid chambers with a temporary filler before manipulating the plate from the first shape to the second shape.

14. The vehicle component of claim 12, wherein, the first explosive tooling process is performed using a first progressive plate and a second progressive plate, and the second explosive tooling process is performed using the first progressive plate after removing the second progressive plate.

15. The vehicle component of claim 12, wherein, the first explosive tooling process is performed using a first progressive plate, and the second explosive tooling process is performed using a second progressive plate after removing the first progressive plate.

16. The vehicle component of claim 12, wherein the molded blank has a laminar flow outer mole line surface.

17. A method for manufacturing vehicle components comprising: forming a plate to have an isogrid pattern, the plate having a first shape; manipulating the plate from the first shape to a blank having a second shape; transforming the blank into a semi-molded blank; and applying an explosive tooling process to the semi-molded blank to form a molded blank.

18. The method of claim 17, wherein forming the plate includes joining two or more plates using a friction stir welding (FSW) process.

19. The method of claim 17, further comprising applying a thermal metallurgical cycle to the semi-molded blank.

20. The method of claim 17, wherein manipulating the plate includes applying a force to one or more areas of the plate, wherein the force causes the first shape of the plate to physically change.

21 . The method of claim 17, wherein manipulating the plate includes supporting the plate using a support structure during a friction stir welding (FSW) process.

22. The method of claim 17, wherein transforming the blank into a semi-molded blank includes: positioning a first end of the blank at a female tool; and applying a force via a male punch at a second end of the blank different than the first end, wherein the force causes a physical property of the blank to change.

23. The method of claim 22, wherein one of a shape of the female tool or a shape of the male punch is output by a tooling machine learning model.

24. The method of claim 17, wherein transforming the blank into a semi-molded blank includes: positioning a first end of the blank at a female tool; applying a first force via a first male punch at a second end of the blank different than the first end, wherein the first force causes a first physical property of the blank to change by a first amount; and applying a second force via a second male punch at the second end of the blank, wherein the second force causes a second physical property of the blank to change by a second amount.

25. The method of claim 17, wherein applying the explosive tooling process includes: placing the semi-molded blank in a female chamber; immersing the semi-molded blank in the female chamber in a fluid; and performing a controlled explosion within the female chamber, wherein the controlled explosion causes a shape of the molded blank to change.

26. The method of claim 17, wherein applying the explosive tooling process includes constraining a portion of the semi-molded blank to a female chamber.

27. The method of claim 17, wherein the at least one of the semi-molded blank or the molded blank is configured for use in a fly-away vehicle.