US 12,404,216 B2
Additive manufacturing methods for forming high-temperature composite structures and related structures
Talbot P. Thrasher, Newark, DE (US); and Timothy E. Dominick, Elkton, MD (US)
Assigned to Northrop Grumman Systems Corporation, Falls Church, VA (US)
Filed by Northrop Grumman Systems Corporation, Falls Church, VA (US)
Filed on Nov. 14, 2023, as Appl. No. 18/508,839.
Application 18/508,839 is a continuation of application No. 16/516,104, filed on Jul. 18, 2019, granted, now 11,814,324.
Prior Publication US 2024/0083823 A1, Mar. 14, 2024
Int. Cl. C04B 35/83 (2006.01); B29C 64/118 (2017.01); B29C 64/30 (2017.01); B29K 71/00 (2006.01); B29K 81/00 (2006.01); B33Y 10/00 (2015.01); B33Y 40/00 (2020.01); B33Y 80/00 (2015.01); C04B 35/622 (2006.01); C04B 35/628 (2006.01); C04B 35/64 (2006.01)
CPC C04B 35/83 (2013.01) [B29C 64/118 (2017.08); B29C 64/30 (2017.08); B33Y 10/00 (2014.12); B33Y 40/00 (2014.12); B33Y 80/00 (2014.12); C04B 35/6224 (2013.01); C04B 35/62272 (2013.01); C04B 35/62844 (2013.01); C04B 35/62886 (2013.01); C04B 35/64 (2013.01); B29K 2071/00 (2013.01); B29K 2081/04 (2013.01); C04B 2235/422 (2013.01); C04B 2235/5232 (2013.01); C04B 2235/5248 (2013.01); C04B 2235/5252 (2013.01); C04B 2235/6026 (2013.01); C04B 2235/616 (2013.01); C04B 2235/656 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method for forming a composite structure, the method comprising:
forming a precursor structure, comprising:
drawing a filament from a spool on which the filament is wound to deposit an amount of filament material; and
drawing more of the filament from the spool to deposit an additional amount of the filament material on the amount of the filament material,
the filament material comprising a precursor matrix material having embedded therein a reinforcing material; and
heating the precursor structure to solidify at least some of the precursor matrix material and form an intermediate structure;
impregnating the intermediate structure with a liquid resin to add carbon or ceramic material to the intermediate structure and form a densified structure; and
heating the densified structure at a temperature between about 932° F. and about 5432° F.