US 12,330,214 B1
Printed porous media, such as for use in aerospace parts, and associated systems and methods
Matthew Perry, Federal Way, WA (US); Lloyd J. Droppers, Renton, WA (US); and Wade Stahl, Kent, WA (US)
Assigned to Blue Origin Manufacturing, LLC, Huntsville, AL (US)
Filed by Blue Origin Manufacturing, LLC, Huntsville, AL (US)
Filed on Feb. 11, 2020, as Appl. No. 16/788,260.
Claims priority of provisional application 62/803,813, filed on Feb. 11, 2019.
Int. Cl. B22F 10/20 (2021.01); B22F 3/11 (2006.01); B22F 10/10 (2021.01); B23K 26/064 (2014.01); B23K 26/34 (2014.01); B33Y 10/00 (2015.01); B33Y 80/00 (2015.01)
CPC B22F 10/20 (2021.01) [B22F 3/11 (2013.01); B23K 26/064 (2015.10); B23K 26/34 (2013.01); B22F 10/10 (2021.01); B22F 2202/11 (2013.01); B33Y 10/00 (2014.12); B33Y 80/00 (2014.12)] 8 Claims
OG exemplary drawing
 
1. A method of manufacturing a porous medium, the method comprising:
selectively heating a first layer of additive material to form an array of first weld beads having a first center, wherein the first weld beads are spaced apart from one another;
selectively heating a second layer of the additive material directly adjacent to the first layer of additive material to form an array of second weld beads having a second center, wherein the second center is laterally offset from the first center, wherein the second weld beads are rotationally offset from the first weld beads by an angle that is not a factor of 360, and wherein the second weld beads are spaced apart from one another; and
selectively heating a third layer of the additive material directly adjacent to the second layer of additive material to form an array of third weld beads having a third center, wherein the second center is laterally offset from the third center, wherein the third weld beads are spaced apart from one another, wherein the first weld beads, the second weld beads, and the third weld beads together form a monolithic structure, and wherein selectively heating the first layer, the second layer, and the third layer includes selectively heating at least one of the first layer, the second layer, and the third layer to attach to a solid portion of a rocket fuel injector so as to directly form the monolithic structure on the solid portion of the rocket fuel injector.