US12578173 - Additively manufactured metal casings

The patent describes a method for additively manufacturing bomb casings using cold-gas dynamic spraying to create a conical nose and cylindrical body, potentially as a single integral piece. The process involves precise control of spray path overlap to ensure optimal layer formation and structural integrity.

Claim 1

1 . A process for additively manufacturing bomb casings defining a generally conical nose portion and a cylindrical body portion, the process including using cold-gas dynamic spraying equipment configured for spraying of metal particles entrained within a gas stream emanating from at least one nozzle to additively manufacture at least one of the generally conical nose portion and/or the cylindrical body portion of the bomb casing, wherein the metal particles as deposited onto a support member form interlaced layers extending in a circumferential direction, wherein a separation distance between adjacent layers is defined by a spray path overlap of the nozzle during cold-gas dynamic spraying of the metal particles forming the adjacent layers and wherein the spray path overlap between adjacent layers is between 30% and 60% of a spray path overlap that would result in minimal overlapping of the two adjacent layers.

Google Patents

https://patents.google.com/patent/US12578173

USPTO PDF

https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/12578173