Novel Manufacturing Methods for Pi-Joints

Invention Reference Number

202205232

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This innovation introduces an automated, cost-effective method for manufacturing Pi-joints, a critical component used to join lightweight structures in industries like aerospace, automotive, and wind energy. By leveraging advanced additive manufacturing and high-rate compression technologies, this approach addresses inefficiencies in traditional methods and supports high-volume production. This innovative Pi-joint manufacturing process streamlines production, enhances quality, and supports the growing demand for lightweight composite structures in diverse industries.

Description

Pi-joints are essential in bonding lightweight composite structures, such as stiffeners to skins in aircraft wings. Traditional manufacturing methods for Pi-joints, which rely on hand layup, injection molding and autoclaves, are time-intensive, labor-heavy, and costly — making them unfavorable for high-volume applications. This invention automates the manufacturing process, eliminates the need for autoclaving, and reduces production time from days to just minutes. Using robotic additive manufacturing, the process achieves controlled fiber orientation and improved bonding quality.

Benefits

Rapid production: Reduces production time.
Cost efficiency: Eliminates manual labor and autoclaving, significantly cutting manufacturing costs.
Scalability: Supports high-volume production for industries like automotive and renewable energy.

Applications and Industries

Aerospace: Joining components for Advanced Air Mobility (AAM) and traditional aircraft.
Automotive: Lightweight and high-strength bonding for electric vehicles.
Wind Energy: Reliable joining of composite structures for wind turbines.